Wire Seal Reinforcement for Connector Terminal Locking
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Solution Overview
Problem
Existing electrical connectors with single wire seals experience unwanted longitudinal motion due to lateral compression, leading to intermittent electrical disconnections and fretting corrosion, as they lack a mechanism to prevent longitudinal compression while allowing lateral compression.
Innovation Solution
A wire seal assembly featuring a rigid seal reinforcement device with a compliant cable seal and housing seal, where the reinforcement device is substantially rigid along one axis and flexible along a perpendicular axis, providing a secondary locking mechanism that inhibits longitudinal motion and maintains terminal alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If lateral compression of the seal is allowed for sealing, then sealing is achieved, but longitudinal compression causes unwanted terminal movement
Solution Approach 1:
The segmented cylindrical structure allows the seal to compress laterally through the gaps between sectors, providing necessary sealing force. Simultaneously, the segmented structure distributes and limits longitudinal compression forces, preventing excessive terminal movement while maintaining sealing effectiveness.
Solution Approach 2:
The wire seal is engineered with anisotropic mechanical properties: highly compliant in the radial direction to provide sealing force, and more rigid in the longitudinal direction to resist terminal movement. The segmented design with controlled gaps enables this directional differentiation of mechanical response.
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 solution effectively reduces longitudinal compression, enhancing the mechanical performance of the secondary locking mechanism, increasing the force required to dislodge the terminal module and maintaining terminal overlap, thus preventing electrical disconnections and corrosion.
Implementation Method 1
a seal reinforcement device configured to be substantially rigid along a first axis
Implementation Method 2
the seal reinforcement device is flexible along a second axis substantially perpendicular to the first axis
Implementation Method 3
a compliant cable seal disposed within the seal reinforcement device and in compressive contact with the wire cable
Implementation Method 4
a compliant housing seal axially surrounding the seal reinforcement device and in compressive contact with the connector housing
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A wire seal assembly (212, 212', 512) configured to seal a wire cable (538) to a connector housing (218, 518) of an electrical connector (210, 510) includes a seal reinforcement device (224, 224', 524) configured to be substantially rigid along a first axis (X). The wire seal assembly (212, 212', 512) also has a cable seal (226, 226', 542) that is disposed within the seal reinforcement device (224, 224', 524) and is in compressive contact with the wire cable (538). The wire seal assembly (212, 212', 512) further incorporates a compliant housing seal axially that surrounds the seal reinforcement device (224, 224', 524). The housing seal (228, 228', 544) is in compressive contact with the connector housing (218, 518).