Watertight Flat-Wire Connector With Compression Seal
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Solution Overview
Problem
Flat-wire conductors in flexible circuits are susceptible to moisture ingress at connection areas without insulating protection, leading to potential electrical failures in vehicles and other systems.
Innovation Solution
A watertight electrical connector system featuring a compression seal that contours to the connection area, using a silicon ring or similar material to create an impermeable barrier around the connector terminals, allowing for variable thickness flexibility and reusability without damaging the flexible circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the insulating body is removed to allow direct connection to flat-wire conductors, then ease of manufacture and device simplicity are improved, but moisture susceptibility increases
Solution Approach 1:
A compression seal acts as an intermediary element between the connector and the flexible circuit board, creating a watertight barrier that prevents moisture ingress while allowing direct connection to flat-wire conductors without requiring an insulating body
Solution Approach 2:
The compression seal utilizes a flexible elastomeric material that can deform to conform to the irregular surface of the connection area, creating an effective moisture barrier while maintaining flexibility and reusability
2Object-affected harmful factors
If a rigid seal structure is used to prevent moisture ingress, then moisture protection is improved, but adaptability to variable thickness and flexibility is worsened
Solution Approach 1:
The compression seal changes its physical parameters (shape, thickness, density) through compression, allowing it to adapt to variable thickness connection areas while maintaining effective moisture protection
Solution Approach 2:
The seal transitions from an uncompressed state to a compressed state, dynamically adapting its properties to match the irregular surface geometry of the connection area, enabling both moisture protection and adaptability
3Object-affected harmful factors
If a compression seal is used to create watertight connection, then moisture protection is improved, but complexity of the device increases
Solution Approach 1:
The connector integrates multiple functions into a single component: electrical connection, mechanical retention, and moisture protection through the integrated compression seal, reducing overall device complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively prevents moisture ingress, ensuring reliable electrical connections even without the insulating body, maintaining the integrity of the flexible circuit and supporting various automotive and non-automotive applications.
Implementation Method 1
a compression seal that contours to the surface of the connection area
Implementation Method 2
A seal surrounds an opening to the cavity to form a watertight connection
Data Source
Figure 1
Figure 2-1
Figure 2-2
AI summary
A watertight electrical connection system to flat-wire conductors of a flexible circuit (112) is described including a watertight electrical connector (100) that houses connector terminals (106) within a cavity (104). A contact surface (102) of the watertight electrical connector (100) is configured to mate with a connection area (120) on a surface of the flexible circuit (112). The connection area (120) is of variable thickness. A seal (110) surrounds an opening to the cavity (104) to form a watertight connection (118) between the connector terminals (106) and one or more of the flat-wire conductors within the connection area (120) on the surface of the flexible circuit (112). A retainer (116) fits over the flexible circuit (112) and onto the watertight electrical connector (100) to compress the seal (110) and form the watertight connection (118) between the surface of the flexible circuit (112) and the contact surface (102), which is of variable thickness.