Modular Back Shell for Circular Connectors
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Solution Overview
Problem
Existing electrical and fiber optic connectors lack versatility and are not adequately designed to be weatherproof and hazard-proof, leading to issues with disconnection due to environmental factors like vibration, and require multiple back shell designs increasing tooling costs and inventory complexity.
Innovation Solution
A modular back shell apparatus with clam shell halves, bellows, and a coupling nut adapter system that allows for secure attachment of cables to connectors, providing strain relief, moisture sealing, and flexibility in angular configurations, while using interchangeable components to accommodate various connector sizes and types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple back shell designs are used for different connectors, then adaptability to various connector sizes and types is improved, but device complexity and inventory complexity increase
Solution Approach 1:
The back shell is designed with a universal interface system that can accommodate multiple connector sizes and types through interchangeable coupling nuts and adapter components. A single back shell design serves multiple functions by accepting different connector configurations without requiring separate back shell variants for each connector type.
Solution Approach 2:
The connector assembly is divided into separable components including the back shell, coupling nuts, and adapter elements. This segmentation allows the back shell to remain a standardized component while different connector types are achieved through interchangeable coupling components, reducing inventory complexity.
2Adaptability or versatility
If multiple back shell styles are manufactured, then adaptability to different applications is improved, but tooling costs increase
Solution Approach 1:
A single back shell tooling design produces a universal back shell that can be configured for different applications through interchangeable coupling nuts and adapters, eliminating the need for separate tooling for each back shell style while maintaining application-specific functionality.
Solution Approach 2:
The system uses interchangeable and reconfigurable components that can be adjusted for different applications without requiring new tooling. The coupling nuts and adapters can be selectively assembled to match different connector types, providing dynamic adaptability with static manufacturing processes.
3Ease of manufacture
If connectors are designed without integral sealing, then manufacturing simplicity is improved, but reliability under environmental conditions deteriorates
Solution Approach 1:
The sealing function is merged with the back shell structure through an integral sealing design where the sealing elements are incorporated directly into the back shell assembly. This combines the structural and sealing functions into a single manufactured component, maintaining manufacturing simplicity while ensuring environmental protection.
Data Source
AI summary
A back shell apparatus receives a cable having conductors extending through the apparatus for attaching to a connector. The back shell includes at least two clam shell halves that mate to surround the conductors. The back shell allows for angular configurations of the cable and connector by including flexible bellows through which the conductors extend. The bellows are respectively expandable and retractable about the conductors. The back shell apparatus further includes a modular cable adapter that receives a respectively sized cable terminus from which the conductors extend into the bellows toward a connector. The back shell apparatus further includes a coupling nut adapter holding a respectively sized coupling nut that mates with the connector.