Self-Leveling Membrane Connector Seal for Moisture Protection
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Solution Overview
Problem
Conventional electrical connectors face issues with weight increase, increased installation time, and unreliable protection due to the use of sealing plugs, and the materials used for sealing membranes may not be optimal for the connector body, leading to potential shearing and interference.
Innovation Solution
A connector design featuring a separate, self-leveling silicone membrane that forms a seal around wire conductors without shearing, allowing the materials for the connector body and sealing membrane to be optimized independently, eliminating the need for sealing plugs and enhancing protection against environmental damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealing plugs are used to protect connector cavities, then protection against moisture and debris is improved, but connector weight increases and installation time increases
Solution Approach 1:
The patent removes the separate sealing plugs from the connector assembly and replaces them with an integrated membrane structure. The membrane is molded directly into the connector body, eliminating the need for separate sealing components while maintaining protection against moisture and debris.
Solution Approach 2:
The sealing function is merged with the connector body structure. The membrane is formed as an integral part of the connector housing, combining the structural support function with the sealing function into a single unified component, thereby reducing overall weight and simplifying assembly.
2Reliability
If sealing plugs are used to seal connector cavities, then protection is improved, but installation time increases
Solution Approach 1:
The membrane is pre-formed and integrated into the connector body during manufacturing, so that the sealing structure is already in place before the connector is installed. This eliminates the need for separate sealing plug installation steps during field installation or assembly operations.
Solution Approach 2:
The sealing function is merged with the connector body structure. The membrane is formed as an integral part of the connector housing, combining the structural support function with the sealing function into a single unified component, thereby reducing overall weight and simplifying assembly.
3Ease of manufacture
If the membrane is made integral with the insert, then manufacturing is simplified, but the membrane material cannot be optimized independently leading to potential shearing
Solution Approach 1:
The patent segments the connector into distinct functional components: the connector body/insert and the membrane. This allows each component to be manufactured from optimally suited materials and processes, then assembled together. The membrane can be made from flexible, tear-resistant material while the insert uses rigid structural material.
Solution Approach 2:
The connector employs composite construction with the membrane and insert made from different materials optimized for their specific functions. The membrane uses flexible, puncture-resistant material while the insert uses rigid structural material, creating a composite assembly that leverages the strengths of each material.
4Reliability
If sealing plugs are used to fill all cavities, then protection is improved, but device complexity increases
Solution Approach 1:
The patent removes the separate sealing plugs from the connector assembly and replaces them with an integrated membrane structure. The membrane is molded directly into the connector body, eliminating the need for separate sealing components while maintaining protection against moisture and debris.
Data Source
AI summary
A connector includes a connector body having cavities with through-holes disposed therein. Sealing membranes are received in the cavities and serve to protect the connector from the environment. Wire conductors may pierce the sealing membranes, and may be received by the through-holes of the cavities in the connector. In cavities in which wire conductors have been received, each sealing membrane forms a seal around a corresponding wire conductor. The connector body is formed from a first material, and the sealing membranes are formed from a second material, different from the first material.