3D Printed Electrical Connector with Epoxy Insert and Elastomeric Seals
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Solution Overview
Problem
Existing electrical connectors manufactured using additive manufacturing technology face challenges in durability and performance, particularly in harsh environments, due to material limitations and structural weaknesses.
Innovation Solution
A three-dimensional printed electrical connector design featuring an insert component with a cavity and sealing members, where the insert component is made of rigid epoxy resin and includes clearance structures and vent holes, and the sealing members are elastomeric and insulating, enhancing robustness and adaptability for additive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrical connectors are manufactured using additive manufacturing technology, then manufacturing flexibility and complexity are improved, but material limitations and structural weaknesses reduce durability and performance
Solution Approach 1:
The patent employs composite material construction by combining rigid epoxy resin for the insert component body with elastomeric sealing members. This composite approach leverages the strength and rigidity of epoxy resin while incorporating the flexibility and sealing capabilities of elastomeric materials, thereby resolving the contradiction between manufacturing flexibility and durability in additive manufactured electrical connectors.
Solution Approach 2:
The patent applies local quality by using different materials for different functional regions: rigid epoxy resin for structural integrity in the insert component body, and elastomeric material specifically for sealing surfaces and sealing members. This localized material selection optimizes both manufacturing flexibility and durability by matching material properties to specific functional requirements.
2Strength
If the insert component body is made of rigid epoxy resin, then structural integrity is improved, but adaptability for complex geometries in harsh environments is reduced
Solution Approach 1:
The patent utilizes parameter changes by modifying the physical and chemical properties of the epoxy resin through additive manufacturing process parameters. By controlling curing conditions, layer orientation, and material composition during 3D printing, the patent achieves both the required structural integrity and the geometric complexity needed for harsh environment applications.
Solution Approach 2:
The patent combines rigid epoxy resin with elastomeric sealing members to create a composite structure that maintains structural integrity while providing the adaptability needed for complex geometries. The elastomeric components compensate for the rigidity of the epoxy resin, enabling the connector to adapt to varying environmental conditions while maintaining structural strength.
3Adaptability or versatility
If clearance structures are added to the cavity, then adaptability for different cavity portions is improved, but device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the cavity into multiple portions with different dimensions and characteristics. The clearance structures are strategically positioned at specific locations within the cavity to accommodate different component sizes and shapes. This segmented approach provides adaptability for various cavity requirements while maintaining a relatively simple overall device structure through the additive manufacturing process.
Data Source
AI summary
A three-dimensional (3D) printed electrical connector includes an insert component, at least a first sealing member, and a shell. The insert component includes a body adapted for 3D printing. The body has first and second ends and includes a cavity penetrating the body along a longitudinal axis of the body. The first sealing member is associated with the insert component and is adapted for 3D printing. The shell at least partially encloses the insert component.