Rigid-Axis Wire Seal Assembly for Stable Connector Terminals

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Solution Overview

Problem

Existing electrical connectors face issues with longitudinal compression of cable seals leading to unwanted movement of terminal modules, causing intermittent electrical disconnections and fretting corrosion, despite the need for lateral compression to seal against environmental contaminants.

Innovation Solution

A wire seal assembly featuring a seal reinforcement device that is substantially rigid along a first axis and flexible along a second axis, combined with compliant cable and housing seals, provides a secondary locking mechanism to inhibit longitudinal motion and enhance mechanical performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If lateral compression of the seal is allowed to form a seal between wire cable and connector housing, then sealing is achieved, but longitudinal compression causes terminal movement in the housing

Engineering Contradiction:

ImprovesealingVSAvoidterminal position stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

Different parts of the wire seal assembly have different mechanical properties tailored to their specific functions. The inner and outer seals are made compliant to allow lateral compression for sealing, while the reinforcement device is made rigid to resist longitudinal compression. This local differentiation of material properties allows each component to perform its function optimally without compromising the other.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The reinforcement device is designed to be flexible in the radial dimension (allowing lateral compression for sealing) while being rigid in the longitudinal dimension (preventing terminal movement). This dimensional differentiation allows the assembly to accommodate sealing requirements in one dimension while maintaining stability in another dimension.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 assembly maintains a robust connection by increasing the force required to dislodge the terminal module and reducing longitudinal compression, ensuring uniform sealing and improved mechanical stability.

Implementation Method 1

a seal reinforcement device configured to be substantially rigid along a first axis

Methodology Applied

Scientific EffectRigidity:

Implementation Method 2

flexible along a second axis substantially perpendicular to the first axis

Methodology Applied

Scientific EffectFlexibility:

Implementation Method 3

a compliant cable seal disposed within the seal reinforcement device and in compressive contact with the wire cable, and a compliant housing seal axially surrounding the seal reinforcement device and in compressive contact with the connector housing

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS12542396B2Electrical connector wire seal assembly that is substantially rigid along a first axis

Publication Date: 2026.02.03 APTIV TECHNOLOGIES AG

AI summary

A wire seal assembly configured to seal a wire cable to a connector housing of an electrical connector includes a seal reinforcement device configured to be substantially rigid along a first axis. The wire seal assembly also has a compliant cable seal that is disposed within the seal reinforcement device and is in compressive contact with the wire cable. The wire seal assembly further incorporates a compliant housing seal axially that surrounds the seal reinforcement device. The housing seal is in compressive contact with the connector housing.