Waterproof Flat Cable Connector with Integrated Sealant Housing
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Solution Overview
Problem
Conventional connectors for flat cables lack a waterproof function, making them unsuitable for use in automobiles and outdoor equipment exposed to weather conditions.
Innovation Solution
A connector design that includes a sealant accommodating section, a relay terminal with a spring terminal and protection wall, and a mating connector with a rubber gasket, providing a waterproof connection between flat cables and electric wires through a connector housing with interlocking hood and mantle sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional connector structure is used, then the connector can be simply manufactured and assembled, but it lacks waterproof function and cannot be used in harsh environments
Solution Approach 1:
The sealant accommodating section is formed by nesting a groove structure within the connector housing body. The housing includes an outer wall with an insertion opening, and the sealant accommodating section is defined by an inner wall that extends from the outer wall to form a recessed cavity. This nested structure allows the sealant to be stored within the housing itself without requiring separate external containers or additional components.
Solution Approach 2:
A flexible sealant member (such as a rubber gasket or sealing film) is used to provide the waterproof barrier. The sealant member is positioned within the sealant accommodating section and can deform to seal gaps between the flat cable terminal section and the connector housing, or between mating connectors, ensuring waterproof protection while accommodating slight variations in assembly tolerances.
2Object-affected harmful factors
If sealant accommodating section is added to provide waterproof function, then the connector can be used in harsh environments, but the structure becomes more complex
Solution Approach 1:
The sealant accommodating section is merged with the connector housing structure itself rather than being a separate component. The housing's inner wall is configured to form the accommodating section, integrating the sealant storage function into the existing housing geometry. This merging approach adds waterproof capability while minimizing structural complexity by using the housing material and form to serve dual purposes.
Solution Approach 2:
The connector housing serves multiple functions: it provides structural support, defines the insertion opening for the flat cable terminal section, and simultaneously creates the sealant accommodating section through its inner wall configuration. This multi-functionality reduces the need for separate dedicated components for each function, thereby adding waterproof capability without proportionally increasing overall structural complexity.
Data Source
AI summary
This connector comprises: a connector housing (11), on one side of which is formed a flat cable terminal-section insertion section (13) wherein a flat cable terminal-section (26) is inserted, and on the other side of which is formed an interlocking hood section (15) wherein a mating connector (5) in an electric wire terminal (100) connected to a flat cable (2) interlocks; and a relay terminal (3) which is accommodated inside the connector housing (11), connects with a terminal fitting (7) in an electrical wire terminal, one end of which is connected to the flat cable terminal-section (26) and the other end of which is accommodated in the mating connector (5), and connects the flat cable (2) and electrical wire (6). A sealant accommodating section (17), wherein a sealant (9) which is attached to the flat cable terminal-section (26) is accommodated, is provided in the flat cable terminal-section insertion section (13).