Ultrasonic Connector Cavity Plug for Vibration-Resistant Sealing
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Solution Overview
Problem
Conventional electrical connector assemblies face issues with unfilled cavities exposing connections to moisture and debris, leading to potential short circuits and malfunction, and existing sealing solutions either fail to positively engage the cavity or increase material costs.
Innovation Solution
An ultrasonically welded plug is designed to securely engage and seal cavities in electrical connectors, minimizing material usage by incorporating an inset portion and recess for alignment and a cap that extends outward to enclose the cavity, while being ultrasonically welded to the connector for a secure fit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plug is inserted into an unfilled cavity to seal it, then the cavity is protected from moisture and debris, but the plug may fall out due to vibrations and movement
Solution Approach 1:
The plug is segmented into multiple functional portions: a head portion for sealing the cavity opening, a body portion for engagement, and an inset portion for ultrasonic welding. This segmentation allows each portion to fulfill its specific function - the head provides the seal, the body provides mechanical engagement through interference fit, and the inset portion provides permanent attachment via ultrasonic welding to the connector body.
2Stability of the object's composition
If a plug with excess structure is used to positively engage the cavity, then the plug remains secure, but material cost increases greatly
Solution Approach 1:
The invention extracts only the essential engagement features needed for secure retention - the inset portion with lateral surfaces for ultrasonic welding and the body portion for interference fit - removing unnecessary excess structure. This minimalistic design achieves positive engagement and secure retention while minimizing material consumption and cost.
Solution Approach 2:
The invention replaces traditional mechanical engagement systems (such as threads, clips, or complex interlocking structures) with ultrasonic welding technology. The inset portion is ultrasonically welded to the connector body, providing a strong, permanent bond without requiring excessive plug structure or complex mechanical retention features.
3Adaptability or versatility
If a standardized electrical connector is used for various components, then assembly is simplified, but some cavities remain unfilled and exposed to elements
Solution Approach 1:
The plug design provides a universal solution that can be applied to any unfilled cavity in standardized electrical connectors regardless of the specific component configuration. The plug's dimensions and engagement features are designed to match standard cavity specifications, allowing it to seal any exposed cavity while maintaining connector compatibility and adaptability across different applications.
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 seals cavities, preventing moisture and debris ingress, and ensures the plug remains securely attached, even under vibrations, while reducing material costs by minimizing the plug's length and using a press-fit design with ultrasonic welding for a watertight seal.
Implementation Method 1
The plug ultrasonically welded to the connector in a configuration
Data Source
AI summary
An assembly includes a plug at least partially disposed in a cavity of a connector at a front end of the connector. The plug ultrasonically welded to the connector in a configuration. The plug includes an inset portion and a recess formed within the inset portion. The inset portion extends axially into a body of the plug. The recess has a first closed surface forming an outer surface and configured to engage with a tool for aligning the plug with the cavity. The plug encloses the cavity with a second closed surface, such that the cavity is free from receiving a terminal or an electrical wire in the configuration.