Dry-Mate Connector Sealing for Deepwater COTS Data Links
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Solution Overview
Problem
Conventional underwater connectors are incompatible with high-speed data communication protocols, prone to signal attenuation and failure, and lack user-friendly, customizable connections for submersible electronic equipment, limiting their suitability for long-term submersion and deep ocean applications.
Innovation Solution
A Dry-Mate Connector System (DMCS) that uses mechanical design components to enclose standard COTS connectors and cables, ensuring proper alignment and locking, allowing for simultaneous high-speed data and power transfer, and supporting various COTS standards, including USB, ethernet, and coaxial connectors, suitable for indefinite submersion and full ocean depth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional underwater connectors are used, then connection between submerged and surface equipment is achieved, but signal integrity deteriorates due to attenuation and corruption
Solution Approach 1:
The patent introduces a specialized connector system as an intermediary between standard COTS cables and the submersible pressure vessel interface. This connector maintains controlled impedance transmission lines and proper signal routing, acting as a mediator that preserves signal integrity while enabling connection between standard cables and underwater equipment.
Solution Approach 2:
The connector design carefully controls physical parameters including transmission line impedance, cable routing geometry, and connector dimensions to maintain signal quality. By optimizing these parameters, the system prevents signal attenuation and corruption that would otherwise occur in conventional underwater connector designs.
2Adaptability or versatility
If custom pin-by-pin cable systems are used, then compatibility with submersible equipment is achieved, but device complexity increases
Solution Approach 1:
The connector system is designed to support multiple COTS cable types and protocols (USB, Ethernet, coaxial) through a single standardized interface on the pressure vessel. This universal design eliminates the need for custom pin-by-pin cable systems while maintaining compatibility with various electronic equipment, thereby reducing overall system complexity.
Solution Approach 2:
The system separates the complex customized connector design from the standard COTS cable end. The pressure vessel side uses a fixed specialized connector, while the cable side remains as standard off-the-shelf components. This segmentation allows versatility without requiring custom cables for each application.
3Ease of operation
If standardized COTS connectors are used directly, then ease of connection is improved, but waterproofing and pressure sealing capability deteriorate
Solution Approach 1:
The connector design nests multiple sealing mechanisms within the connector housing. O-rings and sealing elements are integrated into the connector structure, creating nested barriers that prevent water ingress while maintaining the ability to connect standard COTS cables. This nested sealing approach preserves connection convenience while ensuring waterproofing.
Solution Approach 2:
The specialized connector acts as an intermediary between the waterproof pressure vessel environment and the non-waterproof COTS cables. It provides the necessary sealing function that standard connectors lack, while still enabling easy connection of standard cables to the submersible equipment.
4Reliability
If conventional underwater connectors are used, then submersion capability is achieved, but adaptability to different data communication protocols deteriorates
Solution Approach 1:
The connector system is designed with universal support for multiple data communication protocols including USB, Ethernet, and coaxial connections. The standardized interface on the pressure vessel can accommodate different cable types and protocols without requiring custom connector designs, thereby maintaining both submersion capability and protocol adaptability.
Data Source
AI summary
A Dry-Mate Connector System (DMCS) is capable of a direct and convenient connection/disconnection of standardized Commercial Off-The Shelf (COTS)-compatible data communication cables and connectors with submersible electronic equipment for transmission of data/signals/power therebetween, and is suitable for indefinite submersion, as well as adaptable to full ocean depth. DMCS is equipped with sealing elements, a keying/alignment mechanism for proper alignment of COTS connectors for mating the portions, a locking mechanism to ensure the portions remain locked and pressure sealed, and a dummy plug for sealing the connector when not in use. Functional dummy plugs are contemplated to broaden the functionality.