Modular Harsh Environment Connector In-Situ Assembly
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Solution Overview
Problem
Conventional harsh environment electrical connectors require a labor-intensive and capital-intensive overmolding process, leading to long lead times and limitations in in situ assembly, especially in complex connections, and existing solutions fail to provide cost-effective in situ assembly with a singular sealant junction.
Innovation Solution
A modular harsh environment electrical connector system allowing in-situ assembly, comprising modular components with interchangeable cable and pin configurations, a sealing insert with cavities, and a bulkhead back shell, sealed with materials like epoxy or silicone, enabling flexible and cost-effective installation in extreme environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional overmolding process is used for harsh environment connectors, then environmental tolerance is achieved, but manufacturing lead time increases and labor intensity increases
Solution Approach 1:
The connector is divided into separate modular components (connector body, cable assembly, sealing elements) that can be manufactured independently and assembled in the field. This eliminates the need for time-consuming overmolding while maintaining environmental tolerance through separate sealing mechanisms.
Solution Approach 2:
The connector design enables field technicians to assemble and seal the connector themselves using simple sealing compounds and basic tools, eliminating the need for specialized overmolding equipment and reducing dependency on centralized manufacturing processes.
2Reliability
If conventional overmolding process is used for harsh environment connectors, then environmental tolerance is achieved, but capital investment increases
Solution Approach 1:
By separating the connector into modular components with independent sealing elements, the design eliminates the need for expensive overmolding equipment. Each component can be manufactured using standard processes, significantly reducing capital investment requirements.
Solution Approach 2:
The design uses replaceable sealing compounds and simple sealing elements that are inexpensive to manufacture and replace, eliminating the need for costly overmolding infrastructure while maintaining environmental protection.
3Reliability
If conventional overmolding process is used for harsh environment connectors, then environmental tolerance is achieved, but assembly flexibility decreases
Solution Approach 1:
The modular component design allows different cable assemblies to be paired with compatible connector bodies in the field, enabling flexible adaptation to various applications without requiring retooling or remanufacturing, while each component maintains its environmental tolerance through dedicated sealing elements.
Solution Approach 2:
The connector design allows for dynamic configuration in the field, where cable assemblies can be assembled, disconnected, and reconfigured as needed, providing operational flexibility that rigid overmolded connectors cannot accommodate.
4Adaptability or versatility
If in situ assembly is enabled for modular connectors, then assembly flexibility increases, but sealing complexity increases
Solution Approach 1:
The sealing function is extracted as a separate, simple operation using dedicated sealing compounds applied at specific junctions, rather than being integrated into a complex overmolding process. This allows in situ assembly while keeping the sealing step straightforward and manageable for field technicians.
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 modular connector system reduces manufacturing lead times, allows for cost-effective and flexible assembly in extreme environments, and supports various applications with pressure and chemical tolerance, while maintaining quality and safety.
Implementation Method 1
sealed with materials like epoxy or silicone
Data Source
AI summary
A low cost sealed electrical connector that incorporates multiple connection elements and is sealed against harsh environment with redundant seals. The connector is a harsh environment sealed electrical assembly that is assembled in-situ with a variety of end connector fittings for sealing. The modularity of the sealed connector puck type assembly enables mass manufacturing by injection molding or other mass production methods. The connector can either be mounted to a bulkhead or used in an inline cable assembly using a variety of end fittings. Multiple connector types are encompassed including various sizes of electrical conductors or a combination connector. The connector sealing material is chemical and harsh environment resistant and may include but are not limited to epoxy, urethane and silicone. The invention reduces the number of penetrations in a harsh environment system application thus reducing size, weight, and cost.