Potting Boot Thread Design for Crack Resistance
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Solution Overview
Problem
Conventional potting boots used in electrical connectors for water meters and transmitters in below-ground water pits are prone to cracking and deformation due to environmental exposure and assembly challenges, particularly when molded and ejected from a die, leading to potential weakening and failure.
Innovation Solution
The design includes a potting boot with improved internal thread members having non-uniform cross-sectional shapes and arrangements that radially overlap longitudinal ribs, enhancing gripping and rigidity, and minimizing deformation during the molding and ejection process, thereby reducing the likelihood of cracking and tearing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional potting boots are molded and ejected from a die, then manufacturing productivity is improved, but the boot body becomes prone to cracking and deformation
Solution Approach 1:
The patent modifies the geometric parameters of the thread members by providing non-uniform cross-sectional shapes with varying thicknesses. The thread members have a first thickness at the root and a second thickness at the crest, creating gradient structural properties that allow the boot body to withstand ejection forces without cracking while maintaining manufacturability through conventional molding processes
2Ease of operation
If internal thread members are added to the potting boot, then ease of operation is improved through secure threading, but device complexity increases
Solution Approach 1:
The patent integrates the thread members directly into the boot body structure during the molding process, combining the boot body and threading functionality into a single integrated component. This eliminates the need for separate threading operations or additional parts, maintaining ease of assembly while avoiding the complexity of multi-component construction
Solution Approach 2:
The thread members feature non-uniform cross-sectional parameters with varying thicknesses along their height. The first thickness at the root provides structural support and crack resistance, while the second thickness at the crest enables proper threading engagement. This parameter variation allows a single integrated structure to fulfill multiple functional requirements
3Adaptability or versatility
If the boot body is exposed to harsh environmental conditions, then adaptability is improved for water pit applications, but durability deteriorates due to cracking and deformation
Solution Approach 1:
The patent implements parameter changes by providing thread members with non-uniform cross-sectional thicknesses. The varying thickness creates a gradient structure that enhances crack resistance in the boot body, allowing it to withstand harsh environmental conditions including submersion and temperature variations while maintaining structural integrity and extending service life
Solution Approach 2:
The enhanced structural design with non-uniform thread member thicknesses acts as a preventive measure against cracking and deformation before environmental damage can occur. The gradient thickness distribution preemptively strengthens vulnerable areas of the boot body, cushioning against the harmful effects of harsh environments and extending the operational lifespan
Data Source
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AI summary
An in-line electrical connector includes a potting boot. The potting boot includes longitudinal ribs are spaced apart from one another about a longitudinal axis of a boot body. Internal thread members project radially inward from an interior surface of the boot body relative to the longitudinal axis. The thread members have arcuate lengths extending about the longitudinal axis of the boot body. Each longitudinal rib has an associated one of the internal thread members that radially overlaps an entirety of the width of the longitudinal rib relative to the longitudinal axis of the boot body. An electrical connector threadably mates to the internal thread members of the potting boot. The electrical connector electrically couples to another electrical connector.