Sealed Cylindrical Contact Connector With Low Mating Force
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Solution Overview
Problem
Existing underwater and harsh environment connectors face challenges in maintaining a sealed environment due to high mating and demating forces, structural complexity, and cost, particularly for cylindrical pins which are more robust and suitable for fiber-optic connectors.
Innovation Solution
A connector design featuring elongated cylindrical pins with conductive tips that sealably penetrate resilient passages in an oil-filled chamber, utilizing a tap-and-bore mechanism for sealing engagement without requiring external force, and pressure-balanced chambers to maintain environmental isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid stoppers with robust springs are used to occupy elastomeric receptacle end-seal passages, then the fluid chamber remains sealed from the outside environment, but the structural complexity increases and high mating forces are required to compress the biasing springs
Solution Approach 1:
The patent removes the complex rigid stopper and robust spring mechanism from the elastomeric receptacle end-seal passages. Instead, it uses simple elastomeric material that naturally maintains the sealed state without requiring additional occupying components or strong biasing springs, thereby reducing structural complexity while preserving sealing reliability
Solution Approach 2:
The patent changes the mechanical properties of the end-seal passages by making them elastomeric rather than rigid, allowing them to flexibly maintain sealing without requiring high-force spring mechanisms. This parameter change enables the seal to adapt to mating forces without needing complex occupying structures
2Reliability
If circular tubular end-seal passages are pinched closed with elastomeric sphincters or springs, then the fluid chamber remains sealed, but the mating forces required are substantial and can tear the tubular passage or damage the elastomeric properties
Solution Approach 1:
The patent uses flexible elastomeric material for the end-seal passages themselves, allowing them to naturally conform and seal without requiring additional sphincters or spring mechanisms. This flexible shell approach eliminates the need for high-force pinching mechanisms that could tear the passages or damage elastomeric properties
Solution Approach 2:
The patent removes the elastomeric sphincter and spring components that were previously used to pinch close the tubular passages. The elastomeric material itself is sufficient to maintain the sealed state without requiring these additional force-applying components, thereby reducing mating forces
3Force
If slender plug pins are used to minimize stretching of the sphincter and pinched tube, then the sealing force is reduced, but the pins become easily damaged by bending forces
Solution Approach 1:
The patent uses flexible elastomeric end-seal passages that can accommodate larger-diameter pins without requiring high pinching forces. This eliminates the constraint that forced pin designers to choose between slender (weak) pins and the sealing requirements, allowing for stronger, more robust pin designs
4Strength
If cylindrical pins with rounded cross sections are used, then robustness and uniform electrical field are improved, but the end-seal passages require conforming cylindrical bores that are difficult to seal
Solution Approach 1:
The patent uses flexible elastomeric material for the end-seal passages, which can naturally conform to cylindrical pins with rounded cross sections. This flexibility eliminates the difficulty of creating precise cylindrical bores, as the elastomeric material adapts to the pin shape while maintaining sealing, thereby simplifying the end-seal design
Solution Approach 2:
The patent makes the end-seal passages dynamic and adaptable through the use of elastomeric material that can flex and conform during mating. This allows cylindrical pins to pass through easily while the material naturally seals around them, eliminating the need for precise pre-formed cylindrical bores
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 connector ensures reliable sealing and reduced mating forces, simplifies manufacturing, and is cost-effective while maintaining the robustness and uniform electrical field benefits of cylindrical pins, suitable for both electrical and fiber-optic applications.
Implementation Method 1
a resilient end wall portion including a bore and a tap integrally formed with the resilient end wall portion. The bore and the tap create a sealing engagement therebetween in the absence of an applied force on the tap
Implementation Method 2
at least a portion of each closed chamber is configured to be movable with respect to another portion of the closed chamber to permit balancing of pressure within the closed chamber to pressure outside the closed chamber
Data Source
Figure 1A~1B
Figure 2~3
Figure 4
AI summary
A connector for sealably engaging contacts therein can include a first unit having one or more first contacts that can each include an elongated shaft with a conductive tip. A second unit can have one or more closed chambers therein. Each closed chamber can contain fluid. At least one of the closed chambers can contain one or more second contacts. Each closed chamber can have at least one resilient end wall portion including a bore and a tap integrally formed with the resilient end wall portion. The bore and the tap can create a sealing engagement therebetween when not engaged with the first contact, and create a sealing engagement with the first contact when engaged with the first contact. At least a portion of each closed chamber can be configured to be movable with respect to another portion of the closed chamber.