Pass-through Connector Radial Float Alignment
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Solution Overview
Problem
Existing pass-through connector systems face alignment and sealing issues when connecting electrical devices through panels, leading to faulty connections and potential contamination due to misalignment between the pass-through connector and the header connector, which are often separately mounted.
Innovation Solution
A pass-through connector system featuring a receptacle assembly with a floatable mounting ear and a shroud-guided pass-through connector, allowing for radial movement to align properly with the receptacle assembly during blind mating, ensuring secure and sealed electrical connections across the panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the header connector is separately mounted to the device and the panel is separately mounted to the device, then the mounting process is simplified and the connectors can be installed independently, but misalignment occurs between the header connector and the panel opening, resulting in faulty connections
Solution Approach 1:
The patent introduces a mounting plate as an intermediary component that couples both the header connector and the panel to a common mounting surface. This mounting plate serves as a reference frame that ensures proper alignment between the panel opening and the header connector, eliminating the misalignment issues that occur when components are mounted independently without a common reference.
Solution Approach 2:
The patent combines the mounting functions for the header connector and the panel into a single integrated mounting process using the mounting plate. By merging these mounting operations, the system ensures that both components are positioned accurately relative to each other, resolving the alignment precision problem while maintaining ease of installation.
2Ease of operation
If the pass-through connector is loaded blindly from outside the panel through the opening, then the connection process is simplified, but proper alignment between the pass-through connector and the header connector cannot be achieved, resulting in missed or faulty connections
Solution Approach 1:
The patent implements preliminary alignment actions through the mounting plate that positions the header connector and panel opening in correct alignment before the pass-through connector is inserted. This preliminary positioning ensures that when the pass-through connector is loaded blindly through the opening, it automatically mates with the header connector without requiring visual alignment or complex positioning procedures.
Solution Approach 2:
The mounting plate and the rigid connection between the panel and mounting plate create a self-aligning system where the pass-through connector automatically finds its correct position during blind insertion. The pre-established geometric relationships in the mounting structure guide the connector into proper alignment without requiring external alignment assistance.
3Adaptability or versatility
If the panel is mounted separately from the header connector, then installation flexibility is improved, but gaps and leaks occur at the opening allowing transmission of contaminants, liquids, and pressure through the panel
Solution Approach 1:
The mounting plate acts as an intermediary structure that provides a sealed interface between the panel and the mounting surface. This intermediate component enables separate installation of the panel and header connector while maintaining sealing integrity, preventing contaminants, liquids, and pressure from passing through gaps at the opening.
4Ease of operation
If the aperture diameter is greater than the fastener diameter to allow radial floatability, then alignment during blind mating is improved, but a gap is formed between the mounting ear and fastener that may compromise structural integrity
Solution Approach 1:
The patent uses a flexible seal element that fills the gap between the mounting ear and the fastener. This flexible component maintains the larger aperture diameter needed for radial floatability and alignment while preventing the gap from compromising structural integrity or allowing contaminant ingress. The flexible seal adapts to the dimensional variations while maintaining both alignment capability and mounting strength.
Data Source
AI summary
A pass-through connector system is provided that includes a receptacle assembly and a pass-through connector. The receptacle assembly has a mounting ear at least proximate to a mounting end. The mounting ear defines an aperture therethrough that receives a fastener to mount the receptacle assembly to a substrate. A diameter of the aperture of the mounting ear is greater than an outer diameter of the fastener such that a gap is formed between the mounting ear and the fastener. The pass-through connector extends through a window in a panel that at least partially surrounds the substrate. The pass-through connector has a shroud at a plug end that defines an opening to a cavity. The receptacle assembly is floatable radially within the gap relative to the fastener to allow the shroud to guide the receptacle assembly into alignment with the cavity of the pass-through connector during mating.