Plunger-Sealed Wire Connector for Complete Environmental Isolation
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Solution Overview
Problem
Existing electrical connectors fail to effectively isolate electrical connections from external environmental conditions such as precipitation, humidity, and corrosive substances, leading to potential unintentional grounding or shorting of electrical circuits.
Innovation Solution
A sealed connector design featuring a tubular housing with a plunger cavity and a plunger that includes a compression plate to urge a sealant into the cavity, completely encapsulating the electrical connection and isolating it from the environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If electrical tape is used to wrap electrical connections, then weather and water-resistance is provided, but the adhesive properties fail when exposed to large amounts of liquid
Solution Approach 1:
The patent introduces a two-component sealing system where component A (moldable material) and component B (liquid sealant) act as intermediaries between the electrical connection and the external environment. This sealing system provides superior protection against liquids and environmental factors compared to electrical tape, while the moldable nature allows easy application and adaptation to various connection geometries.
2Object-affected harmful factors
If a housing is used to enclose electrical connections, then isolation from environment is achieved, but leakage occurs when exposed to large amounts of liquid
Solution Approach 1:
The patent changes the sealing mechanism from relying on housing integrity to using a chemical sealant system. Component B is a liquid sealant that chemically bonds or adheres to both the housing and the electrical connection, creating a reliable seal that prevents liquid infiltration even under pressure or immersion conditions.
3Ease of manufacture
If insulating sealant is exposed to external environment, then application is simplified, but the sealant fails due to environmental conditions
Solution Approach 1:
The patent divides the sealant into two separate components: component A (moldable material) applied first to the electrical connection, and component B (liquid sealant) applied afterward to seal component A. This segmentation allows component A to be applied in a controlled manner before exposure to environmental conditions, while component B provides the final protective seal.
4Object-affected harmful factors
If sealant is inserted into housing cavity, then electrical connection is isolated, but the sealant may not completely encompass the junction ends
Solution Approach 1:
The patent employs a two-stage sealing process where component A is first molded or shaped around the electrical connection to provide initial encapsulation, then component B is applied to fill gaps and seal the entire assembly. This dynamic, sequential approach ensures complete coverage of the junction ends and eliminates voids or incomplete encapsulation.
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 sealed connector effectively prevents exposure of the electrical connection to environmental conditions, thereby preventing unintentional grounding or shorting and ensuring reliable electrical connectivity in harsh environments.
Implementation Method 1
The plunger urges the connector toward the closed end of the housing as the plunger is inserted into the plunger cavity
Implementation Method 2
a sealing agent to encompass the electrical connection within the housing to isolate the electrical connection from the external environment
Data Source
AI summary
A sealed connector is provided for electrically connecting a plurality of wires The sealed connector includes a housing defining a cavity adapted for receiving a sealant therein, A plunger is slidably receivable in the cavity of the housing. The plunger defines a passageway through the plunger for allowing the plurality of wires to pass therethrough. A connector Is positionable at an end of the plunger and is configured to electrically connect the plurality of wires. A compression plate extends from an inner surface of the plunger into a passageway through the plunger. The compression plate includes a lower surface configured to urge sealant provided in the cavity toward the connector as the plunger is inserted into the plunger cavity.