Deformable Misaligned Electrical Connector for Poolside Corrosion
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Solution Overview
Problem
Electrical connectors in aquatic environments, such as poolside timing and scoring systems, face corrosion issues due to exposure to chlorinated water, leading to signal degradation and frequent maintenance needs, as conventional connectors with spring members are susceptible to corrosion and electrolysis.
Innovation Solution
A stackable, misaligned, deformable electrical connector system that eliminates the need for conventional spring members by using intentionally misaligned studs and jacks, which deform to create resultant forces for secure contact, allowing the use of corrosion-resistant materials like titanium and preventing water bridges that cause electrolysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional spring members are used in electrical connectors, then contact force is maintained, but corrosion resistance deteriorates due to susceptibility to electrolysis and chlorinated water
Solution Approach 1:
The patent removes the spring member from the connector assembly entirely. Instead of using a separate spring component to provide contact force, the design relies on the inherent deformability of the misaligned stud and jack combination to generate the necessary contact force during insertion and maintenance of electrical connection.
Solution Approach 2:
The patent specifies using titanium or other corrosion-resistant materials for the stud and jack components. These materials provide both the necessary mechanical strength for reliable electrical contact and resistance to corrosion from chlorinated pool water and electrolysis, combining multiple functional requirements into a single material selection.
2Ease of operation
If electrical connectors are positioned on pool deck near water, then timing and scoring components are accessible, but water exposure causes electrolysis and corrosion
Solution Approach 1:
The patent acknowledges that water exposure is inevitable in pool environments but converts this harmful condition into an acceptable scenario by using materials and designs that are specifically resistant to water, chlorine, and electrolysis. The corrosion-resistant materials and misaligned deformable connector design allow the system to function reliably despite continuous water exposure, effectively making the harmful environment irrelevant to connector performance.
3Reliability
If electrical contacts are cleaned frequently to remove corrosion, then signal quality is maintained, but protective layers are abraded and corrosion worsens
Solution Approach 1:
The patent employs titanium or other corrosion-resistant materials that are inherently resistant to degradation from chlorinated water. These materials require minimal maintenance and do not rely on delicate protective layers that need frequent cleaning. The material selection effectively makes the connector contacts resistant to corrosion without requiring aggressive maintenance that would damage protective coatings.
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 solution effectively reduces corrosion and signal degradation, ensuring reliable long-term operation of electrical connectors in corrosive environments by using deformable misaligned connectors that maintain contact over mechanical and abrasion tolerances, and allows for the use of corrosion-resistant materials.
Implementation Method 1
The misalignment creates deformation of at least one of the upper member and the lower member when the first set of connections and the lower connections are plugged together. The deformation creates a resultant force between the first set of connections and the lower connections.
Implementation Method 2
The deformation creates a resultant force between the first set of connections and the lower connections, enabling secure electrical contact without conventional spring members.
Implementation Method 3
The corrosive effect of the pool water can be intensified by electrolysis when the pool water sits in a puddle on hubs or harnesses creating a bridge between the electrical connectors of one or several mating connections.
Data Source
AI summary
A stackable connector system having upper and lower members is provided. The upper member has a first set of upper connections including studs or jacks and a second set of upper connections including studs or jacks that are opposite the first set of upper connections. The lower member includes a first set of lower connections including studs or jacks that are opposite the second set of upper connections. The second set of upper connections and the first set of lower connections have parallel axes that are misaligned in an unplugged state. The misalignment creates deformation of the upper member and/or lower member during insertion of the studs into the jacks when the second set of upper connections and the first set of lower connections are plugged together. The deformation creates a resultant force between the second set of upper connections and the first set of lower connections.