Lateral O-Ring Compression for Waterproof Electrical Connectors
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Solution Overview
Problem
Existing electrical connector systems require significant compressive force for a water-tight seal, especially in larger housings, and are often limited to circular cross-sections, making them cumbersome and unsuitable for a wide range of sizes and shapes.
Innovation Solution
A versatile electrical connector housing system with a latch mechanism that provides a water-tight seal without compressive force along the mating direction, using a curved wall with an o-ring groove and an overlapping shell to laterally compress the o-ring, allowing the latch mechanism to trap the plug housing without applying force along the mating direction, and featuring latch sliders and tabs for secure engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gasket or o-ring is compressed between the plug housing and the receptacle housing to provide a water-tight seal, then the connector achieves water-tight sealing, but the latch mechanism must apply significant compressive force that is well beyond what is required just to securely hold the plug and receptacle together
Solution Approach 1:
The patent changes the direction of o-ring compression from the mating direction (longitudinal) to a lateral direction (transverse). The o-ring groove is positioned on the outer surface of the receptacle housing, and the plug housing's overlapping shell compresses the o-ring laterally as the plug is inserted, rather than requiring longitudinal compressive force from the latch mechanism.
Solution Approach 2:
The patent separates the sealing function from the latching function. The lateral compression mechanism handles sealing independently, while the latch mechanism only needs to provide minimal force to maintain the connection, without being responsible for compression sealing.
2Reliability
If traditional latch mechanisms such as clamps and nuts are used to apply compressive force for sealing, then the connector achieves water-tight seal, but the mechanisms are cumbersome and require significant time and effort to engage and release
Solution Approach 1:
The latch mechanism operates in a direction perpendicular to the mating direction, using lateral movement to engage and disengage. This allows for simpler, faster operation compared to traditional longitudinal clamps and nuts, while still maintaining the connection securely.
3Strength
If threaded collar or twist-lock collar latch mechanisms are used, then the connector achieves secure connection, but these mechanisms are mainly suitable for connector housings which are substantially circular in cross section, limiting versatility
Solution Approach 1:
The latch mechanism design with lateral compression and perpendicular latching is not restricted to circular cross-sections. The overlapping shell and groove configuration can accommodate various housing shapes and sizes, making the connector system universally applicable to different geometries.
Solution Approach 2:
By moving the latching action to a direction perpendicular to the mating direction, the mechanism becomes independent of the housing's cross-sectional shape, allowing it to work with rectangular, oval, or irregular shapes as well as circular ones.
4Ease of operation
If spring-like clipping mechanism latch mechanisms are used, then the connector achieves easy operation, but these mechanisms are suitable mainly for small, lightweight connector housings
Solution Approach 1:
The lateral compression mechanism distributes forces more effectively across the housing structure, allowing the same simple operation mechanism to work with both small and large housings. The overlapping shell provides structural support that enables the mechanism to handle larger, heavier connectors.
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
Enables a water-tight seal without the need for compressive force, suitable for both small and large housings of various shapes, allowing for easy engagement and disengagement, including tool-free options, while maintaining secure connection and preventing inadvertent separation.
Implementation Method 1
compressing an o-ring positioned in the o-ring groove between the curved wall and the overlapping shell. The direction in which the o-ring is compressed is perpendicular to the mating direction of the two housings
Data Source
Figure 1A
Figure 1B
Figure 1C~1D
AI summary
An electrical connector housing system provides a water-tight o-ring seal between a receptacle housing (100) and a plug housing (200) without compressing the o-ring (300) in the mating direction. The housing system includes at least two latch sliders (118) that can be engaged to trap latch tabs (216) within latch slots (116). The latch sliders (118) are substantially unaffected by the o-ring (300) compression, and are compatible with housing systems of almost any size and/or shape. Embodiments include a connector region surrounded by a curved wall (102) having an o-ring groove in its outer surface, and the plug housing (200) includes a shell (202) which overlaps the curved wall (102) and compresses the o-ring (300) perpendicular to the mating direction. The housings can include integral electrical contacts and/or can accept one or more insertable contacts. The latch mechanism can include a detent mechanism, and can require a tool for disengagement.