Deformable Electrical Connector for Corrosive Aquatic Environments
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Solution Overview
Problem
Electrical connectors in aquatic environments, such as pool settings, face corrosion issues due to exposure to aggressive chemicals like chlorine and bromine, leading to signal degradation and potential failure, as conventional materials like metals are susceptible to electrolysis and corrosion when wet.
Innovation Solution
A connector system featuring misaligned, deformable electrical connectors made from corrosion-resistant materials like titanium, which eliminates the need for conventional spring members by creating resultant forces through misalignment, ensuring durable and secure connections despite mechanical tolerances and abrasion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional metal connectors are used in aquatic environments, then electrical connection is achieved, but corrosion occurs due to electrolysis and aggressive chemicals
Solution Approach 1:
The connector employs a composite structure combining titanium (corrosion-resistant but less flexible) with a polymer body (flexible and corrosion-resistant). The titanium contacts provide durable electrical connection points, while the polymer matrix provides flexibility and additional corrosion protection, creating a composite material solution that resolves the contradiction between electrical conductivity and corrosion resistance.
Solution Approach 2:
The invention changes the material parameters by substituting traditional spring materials (beryllium copper alloys) with misaligned titanium contacts embedded in polymer. This parameter change in material composition and structural configuration eliminates the need for flexible metal springs while maintaining connection reliability through the misalignment-induced deformation mechanism.
2Reliability
If spring members are used to compensate for mechanical tolerances, then secure electrical contact is achieved, but spring materials are susceptible to corrosion
Solution Approach 1:
The invention extracts and removes the spring member from the connector system entirely. By eliminating the spring component, the source of corrosion (metal spring in contact with pool water) is removed. The function previously performed by the spring (compensating for tolerances and maintaining contact force) is achieved through the misaligned rigid contacts that deform the polymer body upon insertion.
Solution Approach 2:
The invention substitutes the mechanical spring system with a misalignment-based deformation mechanism. Instead of using elastic deformation of metal springs, the system uses the misalignment between male and female contacts to induce deformation in the polymer body, creating contact force without requiring flexible metal components susceptible to corrosion.
3Ease of operation
If electrical connectors are positioned near the pool for easy access, then ease of operation is improved, but exposure to corrosive pool water increases
Solution Approach 1:
The polymer body of the connector provides chemical inertness and corrosion resistance, allowing the connector to be positioned in accessible locations near the pool without suffering from chemical degradation. The composite structure with titanium contacts maintains electrical functionality while the polymer exterior resists exposure to pool chemicals.
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 system effectively withstands corrosion and maintains signal integrity by using deformation to create contact forces, reducing the need for frequent cleaning and extending the lifespan of electrical connections in corrosive environments.
Implementation Method 1
The misalignment creates deformation of at least one of the upper member and the lower member when the upper connections and the lower connections are plugged together. The deformation creates a resultant force between the upper connections and the lower connections.
Data Source
AI summary
Various embodiments provide a connector system including a plug body and a connector body each having one of studs and jacks with parallel misaligned axes. A deformation of one or more of a plug body, studs, jacks, and a connector body is created when plugging together the misaligned studs and jacks. The deformation creates resultant forces between the studs and jacks for electrical contact. The studs and jacks may be solid metal corrosive-resistant parts, such as titanium, Hastelloy, or Inconel.