Ruggedized Connector Sealing Structure for Dust and Moisture
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Solution Overview
Problem
Existing electrical connectors in harsh environments face challenges in sealing against dust and moisture, leading to potential damage and reduced electrical integrity, and there is a need for a solution that enhances sealing efficiency and contact force adjustment.
Innovation Solution
The development of an adapter connector with a resilient member featuring orthogonal sealing interfaces and a ribbed design that engages with recesses in both the panel and plug connectors, along with a method for adjusting contact force by modifying the compliance of mating contact portions, ensures effective sealing and reliable electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional sealing methods are used in electrical connectors, then the connector can be manufactured with simpler structure, but the sealing effectiveness against dust and moisture deteriorates in harsh environments
Solution Approach 1:
The sealing structure is divided into multiple independent sealing members, each with its own sealing element. The first sealing member engages with the panel opening and the second sealing member engages with the connector body, creating segmented sealing zones that independently address different leakage paths, thereby improving sealing effectiveness without requiring a completely complex integrated structure
Solution Approach 2:
The sealing members are nested within the connector assembly, with the first sealing member positioned in the panel opening and the second sealing member positioned around the connector body. The resilient nature of the sealing elements allows them to be nested compactly while maintaining effective sealing contact surfaces
2Reliability
If fixed contact force is used in connector mating, then the manufacturing process is simpler, but the electrical connection reliability deteriorates under varying environmental conditions
Solution Approach 1:
The contact force is made dynamic through the resilient contact portions that can flex and adapt to varying mating conditions. The contact portions are designed with controlled compliance, allowing them to deform elastically under load and maintain optimal contact force across different environmental conditions such as temperature variations and mechanical stress, thereby improving electrical connection reliability
Solution Approach 2:
The contact force parameter is adjusted by modifying the physical properties of the contact portions, specifically their cross-sectional area and material composition. By changing these parameters, the compliance and elastic modulus of the contact portions are tuned to provide the desired contact force range, enabling reliable electrical connection without complex active adjustment mechanisms
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 provides enhanced sealing against dust and moisture, prolongs the lifespan of seals, and adjusts contact force to suit various environmental conditions, ensuring reliable electrical connections in harsh environments.
Implementation Method 1
a resilient member having first and second sealing elements. The resilient member may be configured to form a first sealing interface with the panel and a second sealing interface with the plug connector
Data Source
AI summary
An electrical interconnection system with an adapter mounted in an opening within a connector interface of a panel of an electronic enclosure is described. A sealing member may be used to prevent passage of foreign matter, such as liquid, gas or dust particles into the enclosure and into the mating region between the adapter and a mating plug connector. The sealing member may comprise a base and a sidewall configured to wrap around an outer border of the adapter. The sealing member may be configured to form a first sealing interface with the panel, and a second sealing interface with the plug connector. The first and second sealing interfaces may be orthogonal to each other. The sealing member may be made of an elastic material.