Unitary Elastic Body Seal for Cable Interconnection
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Solution Overview
Problem
Existing environmental seals for electrical interconnections are prone to degradation from environmental factors like moisture and vibration, are difficult to open, and have limited re-usability, with prior solutions either being non-reusable or having extensive seal areas that degrade over time.
Innovation Solution
A unitary elastic body seal with a bore that includes a cable outer diameter seal portion, a connector cavity portion, a coupling nut cavity portion, a connector neck seal portion, and a bulkhead seal, featuring grip fins or tabs for ease of installation and re-usability, which can be stretched over a coupling nut and bulkhead surface to provide a comprehensive seal without pooling areas for moisture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid clamshell configurations are used for environmental seals, then sealing effectiveness is improved, but ease of operation deteriorates (difficult to open)
Solution Approach 1:
The patent employs a flexible boot made of elastomeric material that can be stretched over the connector assembly and then contracts to form a tight seal. This flexible membrane approach provides both effective sealing and ease of installation/removal, resolving the contradiction between sealing effectiveness and ease of operation.
2Reliability
If gel seals are used for environmental sealing, then sealing effectiveness is improved, but re-usability deteriorates (limited number of re-uses)
Solution Approach 1:
The elastomeric boot can be repeatedly stretched and contracted without degradation, allowing multiple installations and removals while maintaining seal integrity. This reusable flexible membrane replaces the single-use gel seal, resolving the contradiction between sealing effectiveness and re-usability.
3Device complexity
If seal ring with minimal longitudinal extent is used, then device complexity is reduced, but reliability deteriorates (seal degradation over time)
Solution Approach 1:
Instead of increasing the longitudinal extent of the seal ring, the patent uses the radial dimension by providing a boot that surrounds the entire connector assembly. This three-dimensional enveloping approach provides comprehensive sealing coverage without increasing longitudinal complexity, resolving the contradiction between device complexity and long-term reliability.
4Reliability
If C-shaped outer shell with extensive seal area is used, then sealing coverage is improved, but reliability deteriorates (seal degradation from extensive contact area)
Solution Approach 1:
The flexible elastomeric boot provides comprehensive sealing coverage by conforming to the connector assembly shape, while its elastic nature allows it to maintain seal integrity without the degradation issues associated with extensive rigid seal contact areas. The boot can be periodically replaced without affecting the connector assembly.
5Adaptability or versatility
If cylindrical cavity dimensioned to largest connector diameter is used, then adaptability is improved, but volume increases (significant enclosed area for moisture pooling)
Solution Approach 1:
The flexible boot conforms tightly to the actual connector assembly dimensions rather than providing a large cylindrical cavity. This close-fitting approach provides adaptability to different connector sizes while minimizing enclosed volume, preventing moisture pooling while maintaining versatility.
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 solution provides a reliable, reusable seal that effectively resists moisture and vibration, maintaining performance over a wide temperature range while simplifying installation and reducing manufacturing and installation costs.
Implementation Method 1
A unitary elastic body seal with a bore that includes a cable outer diameter seal portion, a connector cavity portion, a coupling nut cavity portion, a connector neck seal portion, and a bulkhead seal
Data Source
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AI summary
A seal for a cable and connector interconnection includes a unitary elastic body with a bore therethrough. The bore is provided with a cable outer diameter seal portion at a cable end, the cable outer diameter seal portion adjacent a connector cavity portion, the connector cavity portion adjacent a coupling nut cavity portion, and the coupling nut cavity portion adjacent a connector neck seal portion with a bulkhead seal at a connector end. The coupling nut cavity portion is longitudinally aligned with a coupling nut of the connector and is provided with a greater inner diameter than the cable outer diameter seal portion and the connector neck seal portion. The bulk head seal is provided with an outer diameter greater than an outer diameter of the connector neck seal portion.