Modular Cable Protection Housing for Sealed Inline Connectors
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Solution Overview
Problem
Existing overmolded electrical connection assemblies are costly and complex to produce, necessitating alternative methods for sealing and protecting in-line electrical components from environmental conditions.
Innovation Solution
A protection device comprising a housing with aligned channels and locking mechanisms to secure an electrical component and cables, utilizing polymeric or elastomeric materials for sealing and impact resistance, simplifying manufacturing and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If overmolded electrical connection assemblies are used to seal and protect electrical components, then protection from environmental conditions is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The protection device is divided into separate modular components: a housing member with cable channels, a sealing member with grommets, and a cover member. These components can be manufactured independently and assembled together, eliminating the need for complex multi-cavity molding processes while providing comprehensive environmental protection for the electrical connection assembly.
Solution Approach 2:
The sealing member with grommets is nested within the housing member, and the electrical connection assembly is nested within the protection device. This nested structure allows multiple protective functions (sealing, mechanical protection, cable management) to be integrated in a compact arrangement without requiring complex molding operations.
2Reliability
If overmolded electrical connection assemblies are used to seal and protect electrical components, then protection from environmental conditions is improved, but production cost increases
Solution Approach 1:
By segmenting the protection device into separate components (housing member, sealing member, cover member), each part can be manufactured using simpler, more cost-effective processes such as injection molding of individual parts or extrusion for the housing, rather than requiring expensive multi-step overmolding operations.
Solution Approach 2:
The sealing member with grommets can be produced as a separate, relatively simple elastomeric component that provides effective sealing without the need for expensive thermoplastic elastomer overmolding. This approach uses cost-effective materials and processes while achieving the required environmental protection.
3Reliability
If multiple layers of overmold are used to seal electrical components, then sealing effectiveness is improved, but material usage and manufacturing complexity increase
Solution Approach 1:
The sealing member incorporates grommets at specific locations where cables penetrate the housing, providing localized sealing exactly where needed. This approach uses material efficiently by concentrating sealing functions at critical points rather than applying multiple layers of material throughout the entire assembly, reducing overall material usage while maintaining effective sealing.
Data Source
AI summary
The present disclosure describes protection devices for electrical connection assemblies. A protection device includes a first housing member having a main body having a length, the first housing member having a main channel, a first and second cable channel that together extend longitudinally the length of the main body, and an identical second housing member configured to be mated and secured to the first housing member via one or more locking mechanisms configured to be received by or engaged with one or more corresponding apertures and/or recesses. When the first and second housing members are mated together, the aligned main channels of the first and second housing members form an internal cavity configured to hold an electrical component therein and the aligned first and second cable channels are configured to hold respective cables connected to the electrical component therein. Other protection devices and related electrical connection assemblies are described herein.