Sealed Electrical Connector with Deformable Wiper
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Solution Overview
Problem
Electrical connectors in corrosive atmospheres, such as salt spray environments, face corrosion issues due to corrosive agents entering the mating threads, reducing their lifespan.
Innovation Solution
An electrical connector design featuring a coupling nut with a sealing member that includes a deformable wiper portion, which flexes between deformed and non-deformed states to seal the interface between the connectors, protecting the threads from corrosion by contacting the outer surface of the complementary connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coupling nut is designed with a sealing member to prevent corrosion, then the reliability and lifespan of the connector is improved, but the device complexity increases due to the additional sealing component and its installation requirements
Solution Approach 1:
The sealing member is nested within a groove in the coupling nut, with the deformable wiper portion extending from the groove to contact the mating connector. This nesting approach integrates the sealing function into the existing coupling nut structure without requiring separate sealing components, thereby improving reliability while minimizing additional complexity
Solution Approach 2:
The deformable wiper portion automatically contacts the outer surface of the mating connector during the coupling process, creating a seal without requiring additional adjustment or installation steps. The sealing action occurs naturally as the coupling nut is threaded onto the mating connector, allowing the system to self-seal and reducing operational complexity
2Manufacturing precision
If a rigid sealing structure is used to seal the mating interface, then the manufacturing precision can be maintained, but the ease of operation deteriorates because the rigid structure cannot accommodate thread misalignment during coupling
Solution Approach 1:
The sealing member transitions from a static rigid structure to a dynamic deformable structure. The wiper portion is designed to deform elastically during the coupling process, allowing it to accommodate misalignment between threads while maintaining sealing contact. This dynamic behavior enables easy operation without sacrificing sealing precision
Solution Approach 2:
The physical state of the sealing member changes from rigid to deformable under operational conditions. The material properties are selected such that the wiper portion can undergo elastic deformation within a specific range, allowing it to adapt to varying alignment conditions during coupling while maintaining effective sealing contact with the mating surface
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 design effectively seals the mating interface, protecting the threads from corrosion and extending the lifespan of the connectors in corrosive environments while maintaining electromagnetic interference (EMI) shielding functionality.
Implementation Method 1
The sealing member is configured to flex between deformed and non-deformed states when coupling the coupling nut to the mating connector
Data Source
AI summary
An electrical connector includes a coupling nut configured to at least partially surround a connector body. The coupling nut includes a first end and a second opposing end. The first end is configured to interface with a mating connector. The coupling nut further includes an inner thread portion located between the first and second ends; and a sealing member located at the first end. The sealing member has a base and a deformable wiper portion. The sealing member is configured to flex between deformed and non-deformed states when coupling the coupling nut to the mating connector. The base of the sealing member is in contact with an inner surface of the first end and the deformable wiper portion extends radially inwardly from the base.