Bayonet Power Connector with Sealed Coupling Ring
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Solution Overview
Problem
Current hermaphroditic power connectors for rail applications require significant manual force to mate and un-mate, are not fully sealed against water and dirt, and often experience polarity issues, limiting their use in harsh environments.
Innovation Solution
A bayonet-style coupling ring mechanism with a twist action for easy mating and un-mating, combined with overmolded polymer grips for comfort and sealing, and internal flat springs for safe disengagement, along with face seals and flat blade contacts to maintain polarity and cleanliness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual push and pull action is used to mate/un-mate connectors, then the connector system is simple in structure, but it requires a lot of force to operate and is not comfortable for the operator
Solution Approach 1:
The connector is divided into separate functional components: a coupling ring for gripping and rotating, a body housing, and internal contact elements. This segmentation allows the coupling ring to provide mechanical advantage through rotation while the internal structure remains relatively simple, resolving the contradiction between ease of operation and structural complexity.
Solution Approach 2:
The coupling ring is designed to rotate dynamically relative to the connector body, transforming the mating operation from a static push-pull action to a dynamic rotational motion. This dynamic mechanism provides mechanical advantage, reducing the force required by the operator while adding only minimal structural complexity.
2Reliability
If current connector systems are used, then the polarity can be crossed at each connection, but the systems are not fully sealed against water and dirt causing mating and un-mating difficulties
Solution Approach 1:
A flexible lip seal is integrated into the coupling ring, extending toward the connector body to create a barrier against water and dirt. This flexible membrane effectively blocks contaminants from entering the mating interface, improving reliability by preventing corrosion and contamination without interfering with the mating operation.
Solution Approach 2:
The lip seal is positioned in advance at the coupling ring to prevent water and dirt from reaching the electrical contacts before contamination can occur. This proactive sealing approach protects the electrical connection reliability by creating a protective barrier prior to any harmful exposure.
3Adaptability or versatility
If hermaphroditic power connectors are used for rail applications, then one connector can interface with the same type of connector, but it requires significant manual force to operate
Solution Approach 1:
The coupling ring incorporates a rotational mechanism that provides mechanical advantage, transforming the force application from direct linear pushing to leveraged rotational motion. This dynamic approach maintains the hermaphroditic compatibility while significantly reducing the manual force required by the operator through the torque multiplication effect of rotation.
Solution Approach 2:
The mating operation is shifted from a one-dimensional linear push-pull action to a two-dimensional rotational motion around the coupling ring axis. This dimensional change provides mechanical advantage through the lever arm of the coupling ring, reducing the force required while maintaining full compatibility between identical connectors.
4Ease of operation
If current connector systems are used, then the structure is relatively simple, but the connectors are not comfortable for the operator to grip and handle
Solution Approach 1:
The coupling ring is constructed as a composite structure combining a rigid base material for structural integrity with an overmolded polymer layer for enhanced grip comfort. This composite design provides both the mechanical strength needed for operation and the ergonomic surface properties for comfortable handling, without excessive structural complexity.
Solution Approach 2:
The overmolded polymer feature is applied locally to specific gripping surfaces of the coupling ring rather than the entire structure. This localized application provides enhanced grip comfort and wet-weather performance where needed, while maintaining the structural efficiency and minimizing the overall complexity of the coupling ring design.
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 provides a mechanical advantage for easy handling, ensures a sealed and reliable electrical connection in all weather conditions, and maintains correct polarity, enhancing usability in harsh environments.
Implementation Method 1
The coupling rings of two connectors are rotated opposite to each other to mate and un-mate the connectors. This provides a mechanical advantage to the operator, which will allow the operator to mate and un-mate the connectors easily
Implementation Method 2
When enough force is applied to the connectors, the pin will ride up the side of the hole and allow the connectors to separate
Implementation Method 3
Each coupling ring may also be provided with a lip seal on its forward end to provide a complete seal of the connectors when mated and a seal of the mating surfaces
Data Source
AI summary
An electrical power connector assembly includes a body having a housing portion and a connection portion; a coupling ring rotatably disposed on the body; and a power connector disposed within the housing portion of the body. The power connector is configured to form a mating engagement with another power connector having the same configuration. The coupling ring is configured to engage a connection portion of another electrical power connector assembly having the same configuration and the connection portion of the body is configured to be engaged by a coupling ring of the other electrical power connector assembly. The coupling ring and the connection portion of the body are configured to engage the connection portion and the coupling ring of the other electrical power connector assembly, respectively, to bring the power connectors together to complete the mating engagement between the power connectors.