Jumper Cable Plug Moisture Seal Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing jumper cable plugs lack a moisture-resistant seal, leading to corrosion of electrical terminals due to exposure to moisture, which can degrade connections and cause faults, especially when salt is present in the moisture.
Innovation Solution
A jumper cable plug with a hollow cylindrical housing featuring an annular groove and a resilient seal ring, which forms a water-resistant seal when mated with a socket, protecting the electrical terminals from moisture and preventing corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional plug and socket connection is used without a seal, then the electrical connection can be easily made and broken, but moisture enters the socket cavity and causes corrosion of the electrical terminals
Solution Approach 1:
A resilient seal ring is added to the plug assembly that forms a flexible barrier between the plug and socket. This seal ring prevents moisture from entering the socket cavity while allowing the plug to be inserted and removed. The flexible nature of the seal ring accommodates the mechanical connection requirements while providing the necessary moisture protection.
2Ease of manufacture
If the plug and socket are mated without a seal, then the connection structure remains simple, but the electrical terminals remain exposed to moisture and salt
Solution Approach 1:
The plug assembly is segmented into separate functional components: the rigid plug body housing and the resilient seal ring. This segmentation allows the seal ring to be independently manufactured and then assembled to the plug body, maintaining manufacturing simplicity while adding corrosion protection functionality.
3Object-affected harmful factors
If a water-tight seal is implemented, then moisture resistance is improved, but the complexity of the plug and socket structure increases
Solution Approach 1:
The sealing function is extracted from the basic plug and socket connection structure. Instead of making the plug and socket themselves complex, a separate seal ring component is introduced that provides the water-tight barrier function, keeping the main connection structure simple.
4Ease of operation
If the electrical terminals are exposed to moisture, then the connection can be accessed easily, but corrosion occurs degrading the electrical connection over time
Solution Approach 1:
The resilient seal ring acts as a flexible barrier that protects the electrical terminals from moisture exposure while allowing the plug to be easily inserted and removed. The seal ring's flexibility ensures it doesn't interfere with the mechanical operation of connecting and disconnecting the plug.
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 effectively prevents moisture from entering the electrical terminals, reducing corrosion and ensuring reliable connections by forming a water-resistant seal between the plug and socket, thus enhancing the durability and performance of the electrical connection.
Implementation Method 1
a resilient seal ring, which forms a water-resistant seal when mated with a socket
Data Source
AI summary
A jumper cable plug for electrically connecting and physically engaging with a socket of the type used in the trucking industry is provided. The plug comprises a hollow cylindrical housing having a front end, a rear end, and a key extending from the front end toward the rear end. An annular grove is provided around the perimeter of the cylindrical housing, and a resilient seal is disposed in the annular grove.