Sealed Snap-In Locking Cavity Plugs for Electrical Connectors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connector assemblies face challenges in securely sealing unoccupied terminal cavities, which can lead to exposure to the external environment, as current methods rely on friction fits that may not be reliable.
Innovation Solution
The use of a locking cavity plug with a resilient locking lance and a compressible seal in unoccupied terminal cavities, combined with a moveable locking feature, ensures secure sealing and retention within the connector assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resiliently compressible elastomeric plug is installed into the unoccupied passage relying on friction fit, then the passage can be sealed from the external environment, but the retention and sealing reliability is insufficient
Solution Approach 1:
The cavity plug is segmented into distinct functional portions: a body portion for sealing, a locking portion with resilient locking lances for retention, and a tail portion for insertion. This segmentation allows each portion to perform its specific function optimally, resolving the contradiction by providing reliable sealing and retention through structured division of functions.
Solution Approach 2:
The resilient locking lances are nested within the body portion of the cavity plug, allowing them to flex and engage with the passage walls while remaining integrated with the seal structure. This nesting provides both sealing and locking functions within a unified component, improving reliability without excessive complexity.
2Adaptability or versatility
If not every passage is occupied by a corresponding cable, then the connector can accommodate unequal numbers of cables, but the unoccupied cavities require additional sealing measures
Solution Approach 1:
The cavity plug serves multiple functions: it seals unoccupied passages from the external environment, provides structural support within the connector body, and maintains the integrity of the sealed environment. This multi-functionality allows the connector to accommodate various cable configurations while requiring only a single type of sealing component, reducing overall complexity.
Solution Approach 2:
The cavity plug is designed as a simple, inexpensive component that can be easily installed and replaced if necessary. Its straightforward construction from dielectric material makes it a cost-effective solution for sealing unoccupied passages, allowing for adaptability without significant complexity or cost increases.
3Ease of operation
If a friction fit is used for retaining the elastomeric plug, then the installation is simple, but the plug may not be securely retained
Solution Approach 1:
The locking portion of the cavity plug incorporates resilient locking lances that dynamically engage with the passage walls. These lances can flex during insertion and then lock into place, providing secure retention while maintaining ease of installation. The dynamic engagement ensures reliable retention without requiring complex installation procedures.
Solution Approach 2:
The resilient locking lances automatically engage with the passage walls upon insertion of the cavity plug, providing self-retention without requiring additional fastening steps or tools. This self-service mechanism ensures secure retention while maintaining simple installation, resolving the contradiction between ease of operation and retention reliability.
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
This solution effectively seals unoccupied cavities, maintaining a weather-tight environment and preventing moisture and contaminants from entering the connector, enhancing the durability and reliability of the electrical connector assembly.
Implementation Method 1
The electrical terminal defines a resilient first locking lance that engages the wall of the first terminal cavity... The cavity plug defines a resilient second locking lance that engages the wall of the second terminal cavity
Implementation Method 2
The electrical cable includes a first seal that is formed of a resiliently compressible material and is configured to seal the cable to the first terminal cavity... The cavity plug includes a second seal formed of a resiliently compressible material that surrounds the plug tail and is configured to seal the plug tail to the second terminal cavity
Data Source
AI summary
An electrical connector assembly includes male and female connector bodies formed with a plurality of terminal cavities in which electrical cables are disposed with the terminals secured against removal from the cavities by flexible lances engaging walls within the terminal cavities. A seal on the cables closes and seals the cavities in which they are installed. At least one of the cavities is unoccupied by a cable and is closed by a non-electrically conductive locking cavity plug. The locking cavity plug has a flexible lance that engages a wall within the unoccupied cavity in which it is installed to secure the plug against removal and carries a seal which engages and seals the unoccupied cavity.