Electrical Connector End-Seal Slitted Passage Design
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Solution Overview
Problem
Existing underwater and harsh environment electrical connectors face challenges in maintaining reliable seals due to complexity, high costs, and reliability issues, such as leaks and contamination, particularly when disconnecting and reconnecting in subsea applications.
Innovation Solution
A connector design featuring blade-like pins and slitted passages with active closure means, including circular springs and leaf spring tines, to ensure the slitted passages remain sealed before, during, and after mating, providing redundant sealing and minimizing stress on the elastomeric material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If robust springs are used to bias stoppers outward in circular end-seal passages, then sealing reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The invention divides the end-seal passage from a circular bore-like structure into a slitted passage configuration. This segmentation allows the elastomeric material to close the passage more effectively without requiring robust springs and stoppers, thereby reducing device complexity while maintaining sealing reliability.
Solution Approach 2:
Instead of using active closure means (springs and stoppers) to push the seal open and relying on passive elasticity to close it, the invention inverts the approach by designing the slitted passage to naturally close through elastomeric resiliency when unmated, eliminating the need for complex active closure mechanisms.
2Reliability
If circular end-seal passages are pinched closed with elastomeric sphincters or springs, then sealing is maintained, but substantial force is required making mating and de-mating difficult
Solution Approach 1:
The invention reverses the traditional approach by eliminating active closure means (sphincters and springs) that require substantial force to operate. Instead, the slitted passage design allows the elastomeric material to naturally close the passage through its own resiliency, requiring minimal force for mating and de-mating while maintaining reliable sealing.
Solution Approach 2:
By segmenting the circular passage into slitted configurations, the invention reduces the force required to open and close the seal. The slitted structure allows the elastomeric material to flex and close more easily compared to pinching a circular passage, thereby improving ease of operation.
3Reliability
If circular tubular passages are pinched closed, then sealing is achieved, but the high stress damages elastomeric properties and creates leak paths
Solution Approach 1:
The invention inverts the stress distribution approach by eliminating the pinching action on circular passages. Instead, the slitted passage design allows the elastomeric material to close through gentle compression rather than high-stress pinching, preserving elastomeric properties and preventing damage that would create leak paths.
Solution Approach 2:
Segmenting the circular passage into slitted configurations reduces the stress concentration on the elastomeric material. The slitted structure distributes the closing force more evenly, preventing the high localized stress that damages elastomeric properties in circular passage designs.
4Reliability
If stoppers are used to occupy end-seal passages, then sealing is maintained, but complex latching mechanisms are required to prevent springing apart
Solution Approach 1:
The invention eliminates stoppers and active closure means by inverting the sealing approach. The slitted passage design allows the elastomeric material to naturally close and maintain sealing without requiring stoppers or complex latching mechanisms to prevent springing apart, thereby reducing device complexity while maintaining reliability.
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 ensures reliable sealing and prevents contamination, maintaining electrical integrity by using active closure mechanisms to augment the resiliency of the slitted passages, making the connector suitable for repeated use in harsh environments with reduced complexity and cost.
Implementation Method 1
a circular spring that exerts a force to urge the passage sealed closed
Implementation Method 2
a leaf spring tine that exerts a force to augment sealing of the passage
Implementation Method 3
a constrictive band seated in a groove in the chamber end-seal that exerts a force to urge the slit-like opening sealed closed
Data Source
AI summary
A plug and receptacle electrical connector can be repeatedly connected and disconnected in harsh environments such as seawater. The plug unit has blade-like pins with insulated shafts and conductive tips. The plug unit engages the receptacle unit housing socket contacts within closed, nested, oil-filled chambers. The chambers are pressure balanced to the in-situ environment and to each other and employ positive means to remain sealed before, during, and after mating and demating.