Rotatable Dry-Mate Connector With Conical Ring Interfaces
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Solution Overview
Problem
Current electrical connector assemblies used in high temperature and high pressure environments require frequent maintenance due to the need for O-rings and central cartridges, which increases the risk of breakdown and failure.
Innovation Solution
A rotatable electrical connector system comprising a coupler with conductive rings and linear contact members, where the connection interfaces are formed in stepped or inverted stepped conic shapes, allowing for fewer components and improved reliability by reducing the need for frequent maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If O-rings and central cartridge are used to provide high temperature and pressure resistance, then reliability is improved, but device complexity increases and maintenance requirements increase
Solution Approach 1:
The patent removes the O-ring and central cartridge components from the connector assembly, replacing them with a simplified design that uses a conical interface with conductive rings directly integrated into the connector body. This extraction of unnecessary components reduces device complexity while maintaining reliability through the direct metal-to-metal contact and conical sealing surface.
Solution Approach 2:
The patent combines the functions of sealing, electrical contact, and mechanical connection into a single integrated conical interface structure. The conductive rings are directly formed as part of the connector body rather than being separate components, merging multiple functions into one unified structure that reduces overall complexity.
2Reliability
If O-rings and central cartridge are used to provide high temperature and pressure resistance, then reliability is improved, but maintenance frequency increases
Solution Approach 1:
By removing the O-ring and central cartridge components that require periodic inspection and replacement, the patent eliminates the maintenance activities associated with these parts. The simplified design with integrated conductive rings and conical interface requires no routine maintenance while maintaining reliability through robust metal-to-metal contact.
Solution Approach 2:
The conical interface design with conductive rings provides self-aligning and self-sealing characteristics that maintain reliable operation without requiring external intervention or maintenance. The structure automatically compensates for minor misalignments and maintains electrical contact through the resilient conductive rings.
3Device complexity
If fewer components are used in the connector assembly, then device complexity is reduced, but achieving high temperature and pressure resistance becomes more difficult
Solution Approach 1:
The patent employs conductive rings made from materials that combine electrical conductivity with high-temperature and pressure resistance. The conductive rings are typically made from phosphor bronze, beryllium copper, or other alloy materials that maintain their mechanical and electrical properties in harsh environments, allowing the simplified design to meet extreme condition requirements.
Solution Approach 2:
The conical interface geometry provides gradual stress distribution and self-aligning characteristics that enhance the connector's ability to withstand temperature and pressure variations. The curved conical surface distributes thermal and mechanical stresses more evenly compared to flat interfaces, improving resistance to extreme conditions without adding components.
4Device complexity
If fewer components are used in the connector assembly, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The conical interface with conductive rings serves multiple functions simultaneously: providing electrical contact, creating a seal, and enabling mechanical connection. This multi-functionality reduces the number of components while the conical geometry itself provides tolerance compensation, reducing the actual precision requirements compared to multiple separate components that would each require precise manufacturing.
Data Source
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AI summary
A coupler for electrical connectors. The coupler includes a body having a first end and a second end opposite the first end. The coupler further includes a first connection interface positioned at the first end of the body, the first connection interface having a first set of conductive rings. The coupler further includes a second connection interface positioned at the second end of the body, the second connection interface having a second set of conductive rings electrically connected to the first set of conductive rings.