Elastomer Moisture Resistant Connector for Aircraft Wiring
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Solution Overview
Problem
Existing connectors used in aircraft and other electrically powered devices exposed to moisture and liquids face electrical failures due to conductive moisture and fluid exposure, as they struggle to maintain adhesion with PTFE-coated wires and metal components, leading to electrical short-circuits and overheating.
Innovation Solution
The use of an elastomer-based connector with multiple integrally molded portions, including a compressible first portion, an extending second portion, and a protruding third portion, made from materials like Viton, which provides a deformable and temperature-resistant seal, replacing traditional epoxy-based designs to ensure moisture resistance and secure connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid epoxy plug is used to encapsulate electrical contacts, then protection from electrical degradation is improved, but adhesion to PTFE-coated wires and metal components deteriorates
Solution Approach 1:
The patent changes the material parameter from rigid epoxy to compliant elastomer, which maintains the protective sealing function while improving adhesion to PTFE-coated wires and metal components through elastic deformation and conformal contact
Solution Approach 2:
The patent uses a composite sealing structure combining elastomer material with metal reinforcement elements (such as stainless steel braid or mesh) embedded within the elastomer, providing both flexibility for adhesion and structural strength for protection
2Object-affected harmful factors
If a rigid epoxy plug is used to encapsulate electrical contacts, then sealing against moisture is improved, but resistance to temperature fluctuations deteriorates
Solution Approach 1:
The patent changes the material from rigid epoxy to compliant elastomer with superior thermal flexibility, maintaining moisture sealing through elastic conformal contact while resisting temperature fluctuations through the material's elastic recovery and thermal expansion properties
Solution Approach 2:
The elastomer material is selected to have thermal expansion characteristics that match or complement the enclosed components, allowing the seal to expand and contract with temperature changes without cracking or losing adhesion to PTFE-coated wires and metal components
3Stability of the object's composition
If a rigid epoxy plug is used to encapsulate electrical contacts, then structural stability is improved, but flexibility for maintaining seal deteriorates
Solution Approach 1:
The patent employs a composite structure where an elastomer matrix provides flexibility and conformal sealing, while embedded metal reinforcement (stainless steel braid or mesh) provides structural stability, combining both properties in a single integrated component
Solution Approach 2:
The patent uses a flexible elastomer shell that can deform to conform to the shape of enclosed components, maintaining sealing contact through elastic recovery, while the overall structure remains stable due to the constrained geometry and reinforcement elements
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 elastomer connector effectively maintains a seal against temperature fluctuations and moisture, preventing electrical failures by ensuring a consistent bond with PTFE-coated wires and metal surfaces, thus providing reliable moisture-resistant connections in hazardous environments.
Implementation Method 1
The use of an elastomer-based connector with multiple integrally molded portions, including a compressible first portion, an extending second portion, and a protruding third portion, made from materials like Viton, which provides a deformable and temperature-resistant seal
Implementation Method 2
The first elastomer portion has a first end adapted to be compressed against a support
Implementation Method 3
provides a deformable and temperature-resistant seal, ensuring a consistent bond with PTFE-coated wires and metal surfaces
Data Source
Figure 1~2
Figure 3~4b
Figure 5~6
AI summary
An elastomer moisture resistant connector for at least one conductor disposed at least partially within a jacket of elastomer material. The connector has a first elastomer portion, which has a first end and a second end. The first end of the first elastomer portion is adapted to be compressed against a support. The connector also has a second elastomer portion that is integrally molded with the first elastomer portion and extends from the second end of the first elastomer portion, and is configured to enclose at least a portion of the jacket. The connector also has a third elastomer portion that is integrally molded with the first elastomer portion, protrudes from the second end of the first elastomer portion, and is adapted to be compressed by an enclosure.