Waterproof Electrical Connector Gas Venting Design
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Solution Overview
Problem
Existing sealed set screw electrical connectors face issues where the last seal may not engage properly during installation and gases expanding due to heat cause sealing caps and conductor seals to be pushed out, leading to water leakage.
Innovation Solution
An electrical connector design featuring a connector body with conductor receiving areas, set screws for clamping conductors, a seal casing, and a valve that allows gas to vent out, along with gas conduits and check valves in the caps to prevent water ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the connector is sealed to prevent water ingress, then water resistance is improved, but gas expansion from heat causes seals to be forced out
Solution Approach 1:
The connector body is divided into multiple sealed compartments, each with its own seal and gas vent. This segmentation allows each compartment to independently manage gas pressure from thermal expansion, preventing the cumulative pressure that would force seals out in a completely sealed system, while maintaining water resistance in each compartment.
Solution Approach 2:
Gas vents are introduced as intermediary components that allow gas to escape from sealed compartments. These vents act as mediators between the sealed environment (which prevents water ingress) and the expanding gas (which would otherwise force seals out), enabling both water resistance and seal reliability to coexist.
2Object-affected harmful factors
If the connector is completely sealed, then water leakage is prevented, but expanding gases push sealing caps and conductor seals out
Solution Approach 1:
The harmful effect of gas expansion is extracted from the sealed system by providing dedicated gas vent pathways. The vents allow expanding gases to be removed from the sealed compartments, eliminating the pressure buildup that would otherwise push sealing caps and conductor seals out, while the sealed structure remains intact to prevent water leakage.
3Object-affected harmful factors
If multiple seals are installed to ensure waterproofing, then water resistance is improved, but the last seal may not stay engaged during installation
Solution Approach 1:
The connector uses multiple segmented seals rather than a single continuous seal. Each seal is installed in a separate compartment and can be independently secured. This segmentation prevents the cumulative pressurization effect that occurs with multiple seals in series, as each sealed compartment manages its own gas pressure independently through its own vent.
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 prevents water leakage by allowing gas to escape while maintaining a sealed environment, ensuring the connector remains watertight even under temperature changes.
Implementation Method 1
The valve is configured to allow gas from inside the at least one conductor receiving area to vent out of the electrical connector
Implementation Method 2
a seal casing on the connector body; and a valve on the connector body
Implementation Method 3
a plurality of set screws connected to the connector body for clamping conductors against the connector body in the conductor receiving areas
Data Source
AI summary
An electrical connector including a connector body having a plurality of conductor receiving areas; a plurality of set screws connected to the connector body for clamping conductors against the connector body in the conductor receiving areas; a seal casing on the connector body; and a valve on the connector body and in communication with at least one of the conductor receiving areas. The valve is configured to allow gas from inside the at least one conductor receiving area to vent out of the electrical connector.