Modular Electrical Connector Preventing Arcing Without Seals
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Solution Overview
Problem
Existing fuel system connectors in vehicles face challenges in maintaining reliable electrical connections while preventing arcing between terminals, which is costly and requires sealing solutions.
Innovation Solution
A modular electrical connector assembly with a flange and receptacle design that maintains a minimum charge separation distance between terminals without seals, using a retention member and error-proofing ribs to secure connectors within a fuel tank, ensuring reliable connections and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealing solutions are used to prevent electrical arcing between terminals, then reliability is improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The patent removes the seal component entirely from the connector assembly. Instead of adding sealing elements to prevent arcing, the design extracts the sealing function by relying on the inherent charge separation distance maintained by the connector's geometric structure, eliminating the need for seals and reducing device complexity
Solution Approach 2:
The patent changes the critical parameter from seal presence to charge separation distance. By designing the connector geometry to maintain a minimum distance between terminal ends (distance A plus distance B), the system prevents arcing through spatial parameter control rather than through sealing materials
2Reliability
If sealing solutions are used to prevent electrical arcing, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent extracts the seal component from the assembly, eliminating the need to source, inventory, and install sealing elements. This reduces manufacturing cost by removing an entire component category while maintaining arcing prevention through geometric design
Solution Approach 2:
The patent replaces expensive sealing materials with a simple geometric configuration that requires no additional materials. The connector body itself, through its molded structure, provides the arcing prevention function at minimal cost
3Adaptability or versatility
If modular architecture is implemented for flexibility, then adaptability is improved, but maintaining charge separation distance becomes more difficult
Solution Approach 1:
The patent segments the connector into modular components (receptacle and plug) while incorporating error-proofing features such as positioning ribs and grooves. These features ensure that when modules are assembled, the terminals automatically maintain the required charge separation distance, combining modularity with precision
Solution Approach 2:
The patent uses asymmetric positioning features (ribs on one side, grooves on the other) to guide modular assembly. This asymmetric design ensures proper orientation and spacing of terminals, maintaining charge separation distance while allowing flexible modular configuration
Data Source
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AI summary
An electrical connector for a modular electrical connection assembly for a fuel system includes a first leg portion and an adjacent second leg portion, each leg portion defining a cavity. The cavity of the first leg portion is configured to receive and maintain a first connector terminal and the cavity of the second leg portion is configured to receive and maintain a second connector terminal without the use of a seal fluidly separating the first connector terminal from the second connector terminal. The first connector terminal and the second connector terminal are concurrently operable with the fuel system.