Dynamic Seal Assembly for Fiber Optic Cable Termini
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Solution Overview
Problem
Conventional fiber-optic cable seals, such as O-ring type seals, fail in high-pressure environments like deep sea underwater applications, and alternative solutions like plastic over-molding increase costs and complexity, while preventing access for repair or replacement.
Innovation Solution
A dynamic seal assembly with a first O-ring seal configuration for low pressures and a second cup seal configuration for high pressures, formed from a single piece of polymer material, which is removable and tunable for differential pressure applications, ensuring effective sealing in both low and high-pressure environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If O-ring type seals are used in fiber-optic cable termini, then the sealing is effective for certain pressure levels, but the sealing fails in high-pressure environments
Solution Approach 1:
The seal assembly transitions from a static O-ring seal to a dynamic multi-configuration seal that can change its sealing mechanism based on pressure conditions. The seal elements are designed to deform and reconfigure under pressure, switching from O-ring configuration at low pressure to cup seal configuration at high pressure, maintaining sealing effectiveness across varying pressure environments
Solution Approach 2:
The seal assembly changes its physical configuration parameters in response to pressure changes. The seal elements are designed with specific geometric parameters that allow them to transition between different sealing modes (O-ring to cup seal) as pressure increases, optimizing sealing performance for each pressure regime
2Reliability
If plastic over-molding is used to seal fiber-optic cables, then sealing in high-pressure environments is achieved, but manufacturing costs and complexity increase
Solution Approach 1:
The seal assembly is segmented into distinct functional portions (O-ring seal portion and cup seal portion) that can be independently designed and manufactured. This segmentation allows for simplified manufacturing of each component while achieving the complex multi-pressure sealing function when assembled, reducing overall manufacturing complexity compared to monolithic plastic over-molding
Solution Approach 2:
The seal assembly is designed as a universal component that performs multiple sealing functions across different pressure ranges. The same assembly provides both low-pressure O-ring sealing and high-pressure cup seal functionality, eliminating the need for multiple specialized sealing components or complex over-molding processes
3Ease of manufacture
If conventional seals are used, then manufacturing is simple, but repair and replacement access is difficult
Solution Approach 1:
The seal assembly is designed as a separable, modular component that can be independently removed from the fiber-optic cable termini housing. This segmentation allows the seal assembly to be manufactured separately using simple processes while enabling easy removal, replacement, and repair without damaging other components or requiring complex disassembly procedures
Data Source
AI summary
Termini assemblies of electrical cable connector assemblies and methods of formation include a termini housing configured to receive an electrical cable and a dynamic seal assembly disposed in the termini housing and including a first portion having an O-ring seal configuration and configured to seal the termini assembly up to a pressure threshold and a second portion having a cup seal configuration and configured to seal the termini assembly at pressures greater than the pressure threshold. Methods of installing the electrical cable connector assemblies include installing the electrical cable connector assembly in a low or high pressure application, wherein installation in the low pressure application results in at least one of the first and second portions of the dynamic seal assembly sealing the termini assembly, and wherein installation in the high pressure application results in the second portion of the dynamic seal assembly sealing the termini assembly.