Moisture-Protected Plug Connection with Integrated Sealing
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Solution Overview
Problem
Existing plug connection arrangements for moisture-proof electrical connections are costly to produce and prone to leaks due to the need for multiple sealing components and insecure screw connections, which can lead to tilting and gaps, especially in applications requiring high sealing standards like underwater use.
Innovation Solution
A plug connection arrangement featuring a form-fitting contact carrier with electrical contacts, a rigid base body, and a sealing element with a surface seal and raised molded seal, along with a detachable sealing element and a cavity filled with low-viscosity potting compound, ensures precise positioning and absolute tightness, while the contact carrier's coding projections prevent incorrect use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple sealing components and screw connections are used to achieve moisture-proof connections, then sealing effectiveness is improved, but device complexity and production costs increase
Solution Approach 1:
The patent combines multiple sealing functions into a single integrated sealing element that includes both a surface seal and a molded seal. This merging of sealing components reduces the total number of parts while maintaining or improving sealing effectiveness, directly addressing the contradiction between reliability and device complexity.
Solution Approach 2:
The sealing element is designed to perform multiple sealing functions simultaneously - the surface seal provides primary sealing while the molded seal provides secondary sealing and structural support. This multi-functionality allows a single component to replace what would traditionally require multiple separate sealing elements, reducing complexity while maintaining reliability.
2Strength
If screw connections are tightened to ensure secure connection, then connection strength is improved, but sealing reliability deteriorates due to tilting and gap formation
Solution Approach 1:
The patent incorporates a compliant sealing element that can deform and accommodate misalignment or tilting before the screw connection is fully tightened. This prior cushioning effect prevents the formation of gaps that would occur with rigid sealing elements, allowing strong screw connections without compromising sealing reliability.
Solution Approach 2:
The sealing element includes a flexible surface seal that can deform to compensate for connection misalignment. This flexibility allows the seal to maintain contact and prevent leakage even when the screw connection causes slight tilting, resolving the contradiction between connection strength and sealing reliability.
3Adaptability or versatility
If different sealing elements and guides are used for different connector variants, then adaptability is improved, but manufacturing complexity and inventory requirements increase
Solution Approach 1:
The patent designs a universal sealing element that can accommodate different connector variants through its flexible surface seal and molded seal structure. The same basic sealing element design can be used across multiple connector types, reducing inventory requirements while maintaining adaptability to different configurations.
Solution Approach 2:
The sealing element's geometry and material properties are optimized to accommodate variations in connector dimensions and configurations. By allowing parameter changes within a unified design framework, the system achieves adaptability to different connector variants without requiring completely different sealing elements for each variant.
4Strength
If a rigid flange with screw connections is used to press against the socket, then connection strength is improved, but ease of operation deteriorates due to risk of incorrect assembly
Solution Approach 1:
The patent incorporates asymmetric features in the connector design, such as coded contacts or asymmetric sealing surfaces, that prevent incorrect assembly. This asymmetry ensures that the connector can only be assembled in the correct orientation, eliminating the risk of polarity reversals or misalignment while maintaining strong screw connections.
Solution Approach 2:
The sealing element is pre-configured to provide sealing contact before the screw connection is fully tightened. This preliminary sealing action prevents incorrect assembly from causing leakage, as the seal engages first and provides immediate feedback on proper alignment, allowing strong connections without risking sealing failure from assembly errors.
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 solution significantly reduces production costs, achieves high sealing efficiency, prevents leaks, and allows for easy replacement of the sealing element, ensuring precise and secure connections even under water, with the added benefit of preventing polarity reversals and assembly errors.
Implementation Method 1
low-viscosity potting compound, which can preferably be filled into the cavity of the base body via a front opening of the contact carrier
Implementation Method 2
the sealing element is then squeezed with its surface seal to such an extent that the contact area of the fastening flange comes into contact with the socket
Data Source
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AI summary
In a plug connection assembly for a moisture-protected electrical plug connection having at least one plug which has a main body (1) having a fastening flange (4) on the front side and a resilient sealing element (7) arranged on said flange and an electric line cable (2) emerging rearward from the main body (1), a contact carrier (5) which receives electric contacts (6) is inserted into the main body (1) in a form-fitting manner. The fastening flange (4) can have a rigid contact area (14) for contact with a socket (9), and the sealing element (7) can have a surface seal (17) and a raised molded seal (27) on a partial surface thereof.