Modular Dielectric Insert for Space Electrical Connectors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connectors fail in extreme thermal cycling environments, such as outer space and earth orbit, due to solder terminations and fluorosilicone material failures, making them unsuitable for long-term use in satellite applications.
Innovation Solution
The development of an electrical connector with a modular dielectric insert that securely holds terminals with both flat and crimp interfaces, and a cable clamp with actuation segments and pressing surfaces that provide strain relief without fluorosilicone materials, ensuring reliable connections in harsh environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solder terminations are used to connect terminals to cable conductors, then electrical connection is achieved, but the connection fails due to extreme thermal cycling in outer space environments
Solution Approach 1:
The patent removes solder entirely from the terminal connection system. Instead of using solder to join terminals to cable conductors, the invention uses mechanical compression through a compression fitting that directly contacts both the terminal and the cable conductor, eliminating the thermal weak point of solder joints in space environments.
Solution Approach 2:
The patent replaces the thermal-based soldering process with a mechanical compression system. The compression fitting applies continuous mechanical force to maintain electrical contact between terminals and cable conductors without requiring thermal bonding, thereby avoiding thermal cycling failures.
2Reliability
If fluorosilicone materials are used in cable clamps and sealing gaskets, then sealing and strain relief are provided, but the materials fail due to extreme thermal cycling
Solution Approach 1:
The patent changes the material parameter from fluorosilicone to a fluoropolymer material that has superior thermal cycling resistance. This material substitution maintains the sealing and strain relief functions while withstanding the extreme temperature variations of space environments over extended periods.
3Ease of manufacture
If a single dielectric insert design is used, then manufacturing is simplified, but the connector cannot accommodate both flat and crimp termination interfaces
Solution Approach 1:
The patent designs a single dielectric insert that performs multiple functions: it provides support and positioning for both flat termination interfaces and crimp termination interfaces. The dielectric insert includes specially designed recesses and features that accommodate different terminal types, allowing one component to serve universal purposes without requiring separate inserts for each termination method.
Data Source
AI summary
An electrical connector includes a shell having a mating end and a termination end. The shell has a securing feature configured to secure the shell to a mating connector. The shell has a cavity that extends between the mating end and the termination end. A terminal subassembly includes a dielectric insert that is configured to be held within the cavity of the shell. The dielectric insert is configured to hold terminals such that mating interfaces of the terminals are configured to mate with corresponding terminals of the mating connector and such that termination interfaces of the terminals are configured to be terminated to a cable. The dielectric insert is a modular insert that is configured to hold the terminals when the termination interfaces are flat interfaces and is also configured to hold the terminals when the termination interfaces are crimp interfaces.