Screw-Down Connector Waterproofing and Locking Mechanism
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Solution Overview
Problem
Existing connectors for portable batteries lack a reliable locking mechanism and waterproofing, leading to accidental disconnection and moisture ingress, especially in rugged conditions, and existing solutions compromise access to controls or provide inadequate protection.
Innovation Solution
A multi-conductor connector with a screw-down locking mechanism and O-ring seal, featuring a right-angle housing with accessible thumb screws and integrally molded flanges, which compresses an O-ring to create a waterproof seal without requiring significant torque changes to the socket retaining members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a large rubber boot is used to cover the connector, then waterproofing is improved, but access to controls and indicators is blocked
Solution Approach 1:
The connector is divided into separate functional zones: a sealed lower portion containing the electrical contacts and a non-sealed upper portion providing access to controls and indicators. This segmentation allows the waterproof boot to cover only the necessary areas while leaving controls accessible.
Solution Approach 2:
The rubber boot is applied locally to specific areas requiring waterproofing rather than covering the entire connector. The boot extends only to the level of the controls, providing waterproofing where needed while maintaining accessibility to buttons and indicators.
2Reliability
If a screw down locking mechanism is added, then resistance to unintentional disconnection is improved, but device complexity increases
Solution Approach 1:
The locking mechanism is merged with the existing connector housing structure. The screw threads engage directly with the housing and contact carrier assembly, eliminating the need for separate locking components and reducing overall complexity.
Solution Approach 2:
The screw down mechanism serves multiple functions: it provides the locking feature to prevent disconnection, compresses the O-ring for waterproofing, and secures the contact carrier. This multi-functionality reduces the need for additional separate mechanisms.
3Reliability
If thumb screws are placed adjacent the rear of the connector, then locking capability is improved, but accessibility for manual operation deteriorates
Solution Approach 1:
The connector housing is designed with a right angle configuration that repositions the thumb screws from a rear location to a side or top location. This dimensional change in the housing structure makes the screws accessible to the user's thumb while maintaining the locking capability.
4Adaptability or versatility
If a retrofit solution is implemented, then adaptability to existing systems is improved, but manufacturing precision requirements increase
Solution Approach 1:
The screw down mechanism automatically performs the alignment and compression functions. As the user tightens the thumb screws, the mechanism self-aligns the O-ring with the contact carrier and applies the necessary compression force, eliminating the need for pre-alignment during installation.
Solution Approach 2:
The compression force applied to the O-ring is controlled by the torque applied to the thumb screws. This parameter change from a fixed compression to a user-adjustable compression allows for proper sealing without requiring extremely tight manufacturing tolerances.
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 a robust, waterproof connection with high pull test scores, allowing easy access to controls while maintaining the existing battery configuration, and can be retrofitted to existing sockets with minimal disruption.
Implementation Method 1
Tightening of the plug screws places an axial force on the flanges, ring and contact carrier which compresses the O-ring. The axial force on the contact carrier compresses the O-ring which is adapted to form a water-tight seal against the socket.
Data Source
AI summary
A plug having a screw-down feature to securely connect to a socket of fixed, existing design. The plug includes flanges with screw receiving bores. Plug screws inserted through the bores deliver a coupling force for a variable compression seal that makes the connection waterproof. The screw-down connection includes upgrading the existing socket machine screws to a socket retaining member. The screw-down feature prevents the plug from accidentally disconnecting from the socket.