Sealed Electrical Connector with Molded Weather-Resistant Sleeve
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Solution Overview
Problem
Conventional electrical connectors for conduits in harsh environments, such as marine and nuclear applications, fail to provide long-term protection against heat, corrosive gases, moisture, and vibration, leading to seal breaches and impaired electrical connections due to improper alignment and loosening of components.
Innovation Solution
Pre-fabricated sealed male and female electrical connectors with molded weather-resistant sleeves and O-ring protection methods that allow for secure, hermetic connections while enabling easy disconnection and reconnection, using a casting process to form insulation around electrical contacts, ensuring water and weather-tight seals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional male and female connector components are used, then electrical connection can be established, but alignment difficulty and installation time increase significantly
Solution Approach 1:
The patent combines the electrical contact and alignment features into a single integrated connector design where the male and female components have complementary geometric features that automatically align during insertion, eliminating the need for separate alignment operations and reducing installation time
2Adaptability or versatility
If repeated movement of connectors is allowed, then adaptability to vibration and movement is improved, but connector loosening and seal breach occur
Solution Approach 1:
The connector design incorporates dynamic sealing features that maintain seal integrity under vibration and movement conditions, with flexible sealing elements that can accommodate relative motion while maintaining contact pressure and preventing loosening
Solution Approach 2:
The connector includes pre-applied anti-loosening features such as lock mechanisms or friction-fit designs that prevent connector components from loosening before vibration or movement occurs, maintaining seal integrity throughout the operational lifecycle
3Object-affected harmful factors
If on-site molding is used for weatherproofing, then weather resistance is achieved, but manufacturing complexity and equipment requirements increase
Solution Approach 1:
The weather-resistant molding is pre-formed and integrated into the connector components during manufacturing, eliminating the need for on-site molding operations and complex mold equipment while ensuring consistent weatherproofing quality
Solution Approach 2:
The connector uses composite material construction with integrated weather-resistant coatings or molded-in sealing features that provide protection without requiring additional molding equipment or complex assembly processes
4Object-affected harmful factors
If on-site molding is used for large diameter conductors, then weatherproofing is provided, but the process becomes difficult and cumbersome
Solution Approach 1:
The molding for weatherproofing is performed in advance during connector manufacturing, creating pre-assembled weather-resistant connector assemblies that are easy to install on large diameter conductors without requiring cumbersome on-site molding operations
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 reliable, long-lasting, and easily maintainable electrical connections that meet or exceed US Navy standards for weather resistance, allowing for secure connections and easy reconfiguration without compromising the seal, even in challenging environments.
Implementation Method 1
fitting an o-ring on the electrical contact... The o-ring prevents the molten mold material from flowing onto the electrical contact
Implementation Method 2
curing the mold material within the mold assembly to form the insulation around the electrical contact
Data Source
AI summary
A sealed connector assembly connects a first cable to a second cable and includes female and male terminal assembly components each having molded in place a weather resistant sleeve that both covers the respective terminal assembly components, and defines openings or gaps which enable female and male contacts to be electrically connected and the sleeves to mechanically contact, thereby providing weather and element resistance. In a method for insulating the respective female and male terminals in a mold assembly, an O-ring applied to the terminal components to prevent liquid mold material from flowing over the electrical contacts.