Magnetic Outdoor Connector Sealing for High-Current Reliability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connector systems for electric vehicles and outdoor electrical devices face challenges in reliability and durability under extreme environmental conditions while transmitting high drive and charging currents, and require improvements in manufacturing ease and waterproofing.
Innovation Solution
A connector system with a plug housing, spring contact pins, magnets, and an insulating casting compound that ensures watertight encapsulation and magnetic coupling for secure alignment and protection against environmental factors, using neodymium magnets for attraction or repulsion based on correct alignment, and a mechanical anti-twist device for added stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the connector is designed with spring contact pins and sockets for high current transmission, then the current carrying capacity is improved, but the reliability under extreme environmental conditions deteriorates due to exposure to moisture and temperature variations
Solution Approach 1:
The patent combines multiple protective functions into a single integrated casting compound that simultaneously provides electrical insulation, moisture barrier, and mechanical protection for the spring contact pins and sockets, allowing high current transmission while maintaining reliability in extreme environments
Solution Approach 2:
The casting compound acts as an intermediary substance that fills the receptacle space around the electrical contacts, creating a protective barrier against moisture and environmental factors while allowing the spring contact pins to maintain their electrical connection functionality
2Reliability
If the connector uses traditional waterproofing methods, then the moisture protection is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent merges the waterproofing function with electrical insulation and mechanical protection into a single casting compound application process, eliminating the need for separate gaskets, seals, or waterproofing layers that would increase manufacturing complexity
Solution Approach 2:
The patent replaces complex mechanical waterproofing systems such as multiple gaskets, seals, and assembly steps with a single chemical casting process that automatically creates a watertight encapsulation, significantly simplifying the manufacturing process
3Reliability
If magnets are added to ensure correct alignment and magnetic coupling, then the connection reliability is improved, but the device complexity increases
Solution Approach 1:
The magnets are permanently embedded in the connector housing to create a self-aligning system that automatically guides the mating connector into the correct position through magnetic attraction, eliminating the need for manual alignment procedures or complex mechanical alignment features
Solution Approach 2:
The magnets serve as an intermediary force field that mediates the alignment process between the two connectors, providing automatic positioning and maintaining consistent contact pressure without requiring precision mechanical tolerances or complex alignment mechanisms
4Reliability
If the entire connector is encapsulated in casting compound for waterproofing, then the moisture barrier is improved, but the repairability deteriorates as the connector becomes disposable
Solution Approach 1:
The patent segments the connector into two distinct parts: the external housing that remains sealed and waterproof, and the internal electrical contact components that are accessible for replacement, allowing the waterproof enclosure to be maintained while enabling repair of the electrical contacts without compromising the moisture barrier
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 system provides reliable and durable operation under extreme conditions, ensuring easy assembly, high current transmission, and effective waterproofing, with magnets enhancing alignment and stability, and a mechanical device preventing incorrect assembly.
Implementation Method 1
the magnets are arranged in the receptacle which surround the spring contact pins and/or sockets, the connector and its connection partner attract each other when the electrical contacts are correctly formed
Implementation Method 2
the magnets are arranged in relation to the corresponding magnets of the connecting partner in such a way that the connector and its connecting partner repel each other if the electrical contacts are incorrectly aligned
Implementation Method 3
the remaining space in the receptacle is cast with an electrically insulating casting compound which acts as a moisture barrier
Implementation Method 4
the remaining space in the receptacle is cast with an electrically insulating casting compound which acts as a moisture barrier
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Connector system with a connector (1) and an associated mating partner (44), wherein: • the connector (1) has a connector housing (12) enclosing a receptacle (14), • the receptacle (14) is closed by a cover plate (24), • several spring contact pins (6) and/or sockets penetrating the cover plate (24) are anchored in the receptacle (14) to form electrical contacts, • a number of magnets (26) are arranged in the receptacle (14) surrounding the spring contact pins (6) and/or sockets, • the remaining space in the receptacle (14) is filled with an electrically insulating and moisture-barrier casting compound (42), wherein the magnets (26) are arranged in relation to associated magnets of the mating partner (44) such that the connector (1) and its mating partner (44) attract each other when the electrical contacts are correctly formed.