Electrical Raft Embedded Conductors Sealed Connector
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Solution Overview
Problem
Conventional electrical harnesses in gas turbine engines are bulky, heavy, and prone to damage due to exposure, leading to increased maintenance time and complexity, with connectors being susceptible to high temperatures and vibrations, and requiring robust yet heavy designs that compromise engine design and efficiency.
Innovation Solution
The use of an electrical raft with embedded conductors and a sealed connector system, where the connector is partially embedded in a rigid material, providing mechanical protection and reducing the risk of damage from contaminants and environmental stressors, while allowing for easier assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional plug or socket connector components are used to connect wires and cables in electrical harnesses, then electrical connection functionality is achieved, but the connectors add weight and complexity to the electrical harnesses
Solution Approach 1:
The patent combines multiple electrical connectors into a single integrated connector component that accommodates multiple conductors. This merging approach reduces the total number of separate connector components needed in the electrical harness, thereby reducing overall complexity while maintaining all necessary electrical connection functions.
Solution Approach 2:
The integrated connector is designed to perform multiple functions simultaneously - it provides electrical connections for multiple conductors, structural support for the wire bundle, and environmental protection through its sealed housing. This multi-functionality eliminates the need for separate components for each function, reducing overall system complexity.
2Reliability
If conventional plug or socket connector components are used in electrical harnesses, then electrical connection is enabled, but the connectors are exposed to engine environment including high temperatures and vibrations
Solution Approach 1:
By integrating multiple connectors into a single unified component with a common housing, the patent creates a consolidated structure that can be collectively protected. The shared housing provides unified environmental protection against heat and vibration, reducing the cumulative exposure risk compared to multiple separate exposed connectors.
Solution Approach 2:
The connector incorporates a sealed housing that acts as a protective shell, enclosing the electrical contacts and internal components. This sealing protects the internal electrical connection elements from direct exposure to harmful environmental factors such as high temperatures, vibrations, and contaminants in the engine environment.
3Reliability
If bulky and heavy connector designs are used to survive engine environment, then connectors can withstand high temperatures and vibrations, but the connectors become even more bulky and heavy
Solution Approach 1:
The patent consolidates multiple connector functions into a single integrated component, eliminating redundant structures. This merging reduces the total weight compared to having multiple separate heavy-duty connectors, while the integrated design maintains environmental resistance through its unified sealed construction.
Solution Approach 2:
The connector housing is made from composite materials that provide high strength and thermal resistance with reduced weight. These composite materials enable the connector to withstand engine environment conditions (high temperatures and vibrations) without requiring excessive material thickness, thus avoiding unnecessary weight increase.
4Adaptability or versatility
If conventional harnesses with multitude of insulated wires and cables are used, then electrical connections can be made, but the harness becomes bulky, heavy and difficult to manipulate
Solution Approach 1:
The patent integrates multiple conductors into a single organized assembly with a unified connector. This merging reduces the number of separate wire manipulations needed during installation and maintenance, making the electrical system easier to handle and manipulate while maintaining all necessary connection capabilities.
5Adaptability or versatility
If conventional harnesses with large number of components are used, then electrical connections can be established, but the assembly process becomes complicated and time consuming
Solution Approach 1:
The patent consolidates multiple connector components into a single integrated unit that can be installed as one piece. This merging dramatically reduces the number of assembly steps and component installations required, thereby increasing assembly productivity while maintaining full electrical connection functionality.
Solution Approach 2:
Multiple connectors are pre-integrated into a single assembled unit during manufacturing. This preliminary action of combining components before installation allows the entire connector assembly to be installed in one operation rather than assembling multiple separate components during field installation, significantly improving assembly productivity.
6Reliability
If protective sleeves and braiding are reinforced to prevent mechanical damage to conductors, then conductors are protected from damage, but the harness becomes even heavier and harder to manipulate
Solution Approach 1:
The connector uses a sealed housing that provides protective enclosure for the conductors and electrical contacts. This shell-based protection is more efficient than heavy reinforcement of individual wire coatings, as it provides collective protection for all conductors within the connector, reducing the need for excessive individual wire reinforcement and thereby reducing overall weight.
Data Source
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Figure 3(a)~3(d)
AI summary
The present invention provides an electrical raft (200) comprising a rigid material (220) having multiple electrical conductors (252) embedded therein. The electrical raft further comprises an electrical connector (700) having a first set of electrical contacts (710) connected to at least one of the electrical conductors, a second set of electrical contacts (720) for electrical connection to another component, and a housing (706) having a first end (702) and a second end (704). The first set of electrical contacts is at the first end and the second set of electrical contacts is at the second end. The first end of the housing is at least partly embedded in the rigid material, and the second end of the housing is accessible from outside the electrical raft, thereby allowing the electrical raft to be electrically connected to said other component. The electrical connector further has a back-shell (740) which sealingly encloses the first end of the housing to prevent ingress of contaminants into the connector.