Two-Piece Locking Connector for Watertight Multi-Pin Sealing
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Solution Overview
Problem
Existing electrical connectors, such as Deutsch Connectors, face issues with water intrusion, corrosion, and mechanical failure in harsh environments, particularly in automotive and marine applications, due to their design as single unitary pieces made of thermoplastic materials, which can crack and allow moisture ingress through electrical cables.
Innovation Solution
A two-piece electrical connector design featuring a connector base made of elastic material and a detachable connector body made of rigid metal, with multiple seals and a locking mechanism, that can be securely attached to a surface without soldering, preventing water ingress and facilitating easy assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Deutsch Connectors are made as single unitary thermoplastic pieces, then water intrusion is prevented, but mechanical strength and resistance to cracking deteriorate
Solution Approach 1:
The connector is divided into two separate pieces: a rigid metal connector body and a flexible connector base. The rigid body provides mechanical strength and structural integrity, while the flexible base provides sealing and water intrusion prevention. This segmentation allows each component to optimize its material properties for its specific function.
2Ease of manufacture
If flange mounted Deutsch Connectors are used, then mounting to surface is achieved, but ease of operation deteriorates due to difficulty in plugging and unplugging
Solution Approach 1:
The connector base is made of flexible elastic material that can dynamically deform during connection and disconnection operations. This flexibility allows the connector to accommodate insertion forces and be easily removed by pulling, unlike rigid flange-mounted connectors that require significant force and can crack.
3Reliability
If Deutsch Connectors are made as single unitary structure, then water intrusion points are limited, but ease of repair deteriorates when damage occurs
Solution Approach 1:
The detachable two-piece design allows the connector body to be separated from the connector base. When damage occurs, only the affected component needs to be replaced, not the entire connector assembly. This significantly simplifies repair operations compared to unitary connectors where the entire structure must be replaced.
4Strength
If rigid thermoplastic material is used for Deutsch Connector, then structural integrity is maintained, but adaptability to harsh environments deteriorates
Solution Approach 1:
The connector combines two different materials: rigid metal (providing structural integrity, strength, and durability) and flexible elastic material (providing sealing, flexibility, and environmental adaptability). This composite construction allows the connector to withstand harsh environments including temperature extremes, vibration, and moisture while maintaining structural strength.
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 two-piece connector provides a watertight seal, reduces the risk of mechanical failure, and simplifies the assembly process by eliminating the need for soldering and wire feeding, thereby enhancing durability and reliability in wet and rugged environments.
Implementation Method 1
The connector base is made of elastic material
Data Source
AI summary
A waterproof seal for electrical assemblies wherein at least two pins extend through the electrical conductor such that the at least two pins extending from a distal end of the electrical conductor and are adapted to interact with openings on a connecter that is detachably connectable with the distal end of the electrical connector, and the at least two pins extend from a proximal end of the electrical connector such that the at least two pins extending from the proximal end are adapted to be interact with openings in a socket formed in the surface of housing where the electrical connector forms a water tight barrier preventing water from entering the housing through the electrical connector or around the electrical connector.