Moisture Resistant Seal for Heavy-Duty Truck Plug
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Solution Overview
Problem
Moisture and debris ingress into plug-and-socket connections of heavy-duty truck and trailer electrical systems causes corrosion and degradation of electrical connections, leading to unreliable connections between the tractor and trailer.
Innovation Solution
A moisture-resistant seal is formed by a seal ring with a cross-section matching the plug housing and electrical connection holder, ensuring alignment and secure mating between the plug and socket, with a locking mechanism to prevent accidental disconnection and a design that includes ribs for drainage and a resilient material to prevent moisture entry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional plug-and-socket connection is used without a seal, then the device complexity is reduced and ease of manufacture is improved, but moisture and debris can ingress into the electrical connections causing corrosion and degradation
Solution Approach 1:
The seal is nested within a groove in the plug housing, with the seal protrusion fitting into the socket cutout. This nesting arrangement allows the seal to be integrated into the existing plug structure without adding external components, thereby improving reliability by preventing moisture ingress while minimizing increases in device complexity
Solution Approach 2:
The seal is made of resilient material that can deform to conform to the groove geometry and maintain contact with the socket cutout. This flexible seal design effectively blocks moisture and debris from reaching electrical connections, improving reliability without requiring complex rigid sealing mechanisms
2Manufacturing precision
If a seal with cross-section matching the housing and connection holder is used, then alignment precision between plug and socket is improved, but manufacturing precision requirements are increased
Solution Approach 1:
The seal cross-section is designed to match the asymmetric profile of the housing and connection holder, with the seal protrusion having a specific shape that corresponds to the socket cutout. This asymmetric design provides positive alignment features that guide the plug into correct orientation during mating, improving alignment precision while the seal groove is formed as an integral feature of the housing
3Reliability
If a locking mechanism is added to prevent accidental disconnection, then reliability of the electrical connection is improved, but device complexity and ease of operation are worsened
Solution Approach 1:
The housing protrusion and socket cutout create a preliminary mechanical interference fit that prevents accidental disconnection. The seal protrusion engages with the cutout to lock the plug in place, while the resilient nature of the seal allows for controlled release when intentional removal is needed, balancing connection stability with ease of operation
Data Source
AI summary
An electrical plug configured to be mated with a socket, the electrical plug including a substantially tubular plug housing having a front end, a rear end, a side wall between the front end and the rear end, and a housing protrusion on the side wall and configured to be inserted within a socket cutout of the socket, a groove proximate the front end of the housing, and a seal located in the groove and having a cross-section with an outer surface that is substantially similar to an outer surface of a cross-section of the side wall and the housing protrusion.