Electrical Connector Contact Potting for Leak-Free Assembly
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Solution Overview
Problem
Conventional electrical connectors require multiple assembly steps and often have leakage points that increase the risk of electrical shorting due to air gaps between insert components.
Innovation Solution
A method involving a temporary contact holder to orient contacts within a connector housing, followed by the addition of a flowable curable material to fill a cavity and surround the contacts, eliminating the need for multiple insert components and reducing assembly steps, while ensuring a secure and sealed environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple separate insert components (grommets, front and rear insert portions) are assembled to hold contacts, then the connector can be made with conventional methods, but the manufacturing process becomes complex and time-consuming with many assembly steps
Solution Approach 1:
The patent combines multiple separate insert components (grommets, front insert portion, rear insert portion) into a single integrated insert component. This consolidation eliminates the need for multiple assembly steps while maintaining the functional capabilities of holding and sealing contacts, directly resolving the contradiction between ease of manufacture and device complexity
Solution Approach 2:
The single insert component performs multiple functions that were previously distributed across separate components: it holds contacts, provides sealing, and structures the internal cavity. This multi-functional design simplifies manufacturing while maintaining comprehensive functionality, addressing both ease of manufacture and device complexity
2Ease of manufacture
If multiple separate insert components are assembled, then the connector can be constructed with conventional methods, but assembly time and manufacturing steps increase significantly
Solution Approach 1:
By merging multiple insert components into one integrated component, the patent reduces the number of assembly operations required. This single component can be installed in one step rather than requiring sequential assembly of multiple parts, directly improving productivity while maintaining ease of manufacture
Solution Approach 2:
The insert component is pre-assembled and integrated before installation into the connector housing. This preliminary integration of multiple functions into a single component eliminates the need for on-site assembly of multiple parts, thereby increasing manufacturing productivity
3Ease of manufacture
If separate insert components are used, then the connector can be made with conventional assembly methods, but leakage points and air gaps increase the risk of electrical shorting
Solution Approach 1:
The integration of multiple insert components into a single unified component eliminates the interfaces and joints between separate parts. This removal of interfaces eliminates potential leakage points and air gaps, thereby improving electrical reliability and preventing shorting while maintaining ease of manufacture
Solution Approach 2:
The patent converts the potential harm of multiple interfaces between separate components (which create leakage paths) into a benefit by integrating those interfaces into a seamless single component structure, eliminating air gaps and improving reliability
4Productivity
If a single integrated insert component is used, then manufacturing time is reduced and assembly is simplified, but the component must perform multiple functions previously distributed across separate parts
Solution Approach 1:
The single insert component is designed to perform multiple functions (contact holding, sealing, cavity structuring) that were previously distributed across separate components. This multi-functionality increases productivity by reducing assembly steps while the integrated design manages the complexity internally, presenting a simpler external interface
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
This method significantly reduces manufacturing time, eliminates leakage paths, and enhances electrical performance by eliminating air gaps, thus reducing the risk of electrical shorting and improving hermiticity.
Implementation Method 1
adding, e.g. by pouring or injecting, a flowable curable material into the pour receiving cavity to at least partially fill the pour receiving cavity
Implementation Method 2
adding, e.g. by pouring or injecting, a flowable curable material into the pour receiving cavity
Data Source
AI summary
Electrical connectors and methods of making the connectors. The method steps include inserting one or more contacts into a temporary contact holder; removably coupling the contact holder with a connector housing, thereby creating a pour receiving cavity inside of the housing; adding a flowable curable material into the cavity to at least partially fill the cavity and surround at least part of the contacts residing in the connector housing; and removing the contact holder from the connector housing, thereby leaving mating contact ends of the one or more contacts exposed and leaving the mating contact ends set in the ready position for mating with a complementary connector.