Connector Assembly With Segmented Male Plug
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Solution Overview
Problem
Existing electrical or fiber-optic connectors lack improved performance and effective sealing integrity, particularly in moisture and water resistance, with negligible coupling forces between male and female members only at the end of axial movement.
Innovation Solution
The connector design features a male plug with increasing cylindrical diameters along its length and a corresponding female receptacle, ensuring negligible coupling forces until the end of insertion, enhancing sealing through varying diameters and dual sealing elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the male plug segments have substantially equal cylindrical diameters, then the connector structure is simpler, but the sealing performance and coupling force distribution are insufficient
Solution Approach 1:
The male plug is divided into multiple segments (first, second, and third segments) with progressively increasing diameters. Each segment can engage with corresponding segments in the female connector, allowing the sealing function to be distributed across multiple interfaces rather than relying on a single sealing point, thereby improving overall sealing reliability.
Solution Approach 2:
Different segments of the male plug are assigned different diameters to create localized variations in coupling characteristics. The larger-diameter segments provide enhanced sealing surfaces and distributed coupling forces, while smaller-diameter segments allow for gradual engagement. This local differentiation optimizes sealing performance at critical interfaces.
2Reliability
If coupling forces are present throughout insertion, then connection stability is improved, but insertion force requirements increase and sealing at final position is reduced
Solution Approach 1:
The connector segments are designed to engage in a predetermined sequence during insertion, with smaller-diameter segments engaging first and larger-diameter segments engaging later. This preliminary engagement sequence allows the connection to stabilize progressively, with final sealing occurring at the larger-diameter interfaces when the full coupling force is applied, optimizing both stability and sealing.
3Ease of manufacture
If uniform diameters are used for all segments, then manufacturing is simpler, but sealing redundancy and moisture resistance are insufficient
Solution Approach 1:
The multi-segment design creates a nested engagement structure where smaller-diameter segments are positioned within or alongside larger-diameter segments. This nested arrangement provides multiple concentric sealing interfaces, creating redundant barriers against moisture and water ingress while maintaining a compact overall structure that is manageable during manufacturing.
Data Source
AI summary
An improved connector assembly is disclosed wherein end segment portions of a male plug have increasing cylindrical wall cylindrical wall diameter from the outer-most segment to an intermediate segment to an inner segment. The female receptacle has its female receptacle dimensions arranged to accept the male plug such that increasing cylindrical wall diameters exist from its outer-most segment to an intermediate segment to an inner-most segment. The increased diameters enhance the sealing with a strong and sustainable sealing pressure wherein coupling forces between the male plug and female receptacle are minor until the end of the insertion of the male plug into the female receptacle.