Crimp Pin Connector Sealing Structure for Fluid Leak Prevention
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Solution Overview
Problem
Crimp pin electrical connectors in aircraft systems are prone to fluid leakage, which contaminates local electrical components and leaks externally, due to the leakage path extending from the wire lead insulation to the inspection hole, located outside the seal, compromising the integrity of the connection.
Innovation Solution
A crimp pin electrical connector design featuring a housing with a flange that forms a seal between the wet and environment regions, incorporating an interfacial seal, dielectric insert, grommet, and seal barriers to prevent fluid transfer, and a crimp pin that extends through the flange to stabilize the connection and prevent leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the crimp pin electrical connector uses a conventional design with inspection hole and wire lead insulation exposed on the external side of the seal, then the connector allows for inspection and assembly, but fluid leakage occurs from the wire lead insulation to the inspection hole
Solution Approach 1:
The inspection hole is removed from the housing structure entirely. Instead of providing an inspection opening that compromises the seal, the patent uses non-destructive inspection methods such as X-ray or ultrasonic testing to verify crimp quality and connector assembly, thereby maintaining fluid sealing integrity while enabling quality assurance.
Solution Approach 2:
A fluid barrier or seal member is introduced between the wire lead insulation and the external environment. This intermediary element prevents fluid from reaching the wire lead insulation and inspection hole, effectively blocking the leakage path while allowing the connector to maintain its inspection and assembly capabilities.
2Stability of the object's composition
If the crimp pin extends through the flange to stabilize connection, then connection stability improves, but the complexity of the connector structure increases
Solution Approach 1:
The crimp pin is integrated with the housing structure, where the pin and housing form a unified assembly. The crimp pin extends through the flange and is directly formed as part of the housing or attached as a single integrated component, reducing the number of separate parts while maintaining connection stability.
Solution Approach 2:
The crimp pin serves multiple functions: it provides electrical connection, mechanical stabilization, and structural support for the flange. By combining these functions into a single component, the design achieves connection stability without proportionally increasing overall structural complexity.
Data Source
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AI summary
A crimp pin (128) electrical connector (40) comprising a shell (100) defining an interior (102) with a first opening (44) and a second opening (46), a flange (48) circumscribing the shell (100), an insert located within the interior (102) and extending through the first opening (44). The insert comprising at least one crimp pin (128) including a crimp (140) and a pin (138) provided within at least one passage (122) included within the interior (102) of the shell (100).