Tool-less Service Cable Connector Weatherproof Sealing
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Solution Overview
Problem
Traditional threaded bushing systems for service cables in outdoor environments are cumbersome to install and difficult to ensure are weatherproof, requiring specialized tools and precise torque measurements, leading to unreliable connections and potential water ingress damage to electronic components.
Innovation Solution
A tool-less mechanical connector system that uses a cylindrical service jacket receiver with a frustoconical weather gasket and coupling nut, allowing for a weatherproof seal to be achieved without specialized tools, by compressing the gasket between the nut and the enclosure bushing using hand-applied force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If threaded bushing systems with multiple O-rings and screw seals are used, then weatherproof connection is achieved, but installation complexity and time increase significantly
Solution Approach 1:
The connector is divided into distinct modular components: a housing with integrated seal, a cable assembly with pre-attached grommet, and a coupling mechanism. This segmentation allows each component to be optimized independently and simplifies the installation process by eliminating the need for assembling multiple small parts like traditional threaded bushings with separate O-rings and screw seals.
Solution Approach 2:
The patent merges the sealing function directly into the housing structure through an integrated grommet and seal assembly, combining what were previously separate components (housing, O-rings, screw seals) into a unified weatherproof connector. This merging reduces the number of parts and simplifies installation while maintaining reliable weatherproofing.
2Reliability
If threaded bushing systems with torque-measuring wrenches are used, then weatherproof seal is ensured, but ease of operation deteriorates
Solution Approach 1:
The connector design incorporates self-aligning and self-sealing features where the housing and cable assembly automatically position and seal together without requiring external torque measurement tools. The integrated grommet and coupling mechanism provide inherent guidance and sealing action, making the installation process accessible to technicians without specialized equipment.
Solution Approach 2:
The patent replaces the complex mechanical torque-measurement system with a simplified coupling mechanism that uses direct engagement and inherent mechanical advantage. The design eliminates the need for torque-wrenches by using a coupling system that naturally achieves proper sealing through its geometric design and material properties.
3Reliability
If multiple threaded sections with O-rings are used, then weatherproof connection is achieved, but installation time increases
Solution Approach 1:
The cable grommet and seal components are pre-attached to the cable assembly during manufacturing, and the housing seal is pre-integrated into the connector body. This preliminary preparation eliminates the need for field technicians to assemble multiple O-rings and seal components during installation, significantly reducing installation time while ensuring proper weatherproofing.
Solution Approach 2:
The patent combines multiple sealing functions into single integrated components - the housing contains built-in seal structures, and the cable assembly has pre-attached grommets. This merging of sealing functions into unified components reduces the number of installation steps from assembling multiple separate seals to a single coupling action.
4Reliability
If torque-measuring wrenches are required for each threaded screw seal, then connection reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent employs inexpensive, pre-formed seal components (grommets and integrated housing seals) that are mass-produced and discarded after single use, replacing expensive torque-measuring tools and complex threaded bushing systems. These simple seal components provide reliable weatherproofing at low cost without requiring specialized installation equipment.
Solution Approach 2:
The design replaces the expensive torque-measurement mechanical system with a simplified coupling mechanism that achieves reliable sealing through geometric design and material properties rather than precision torque control. This substitution eliminates the need for costly specialized tools while maintaining connection reliability.
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 system simplifies the coupling process, ensures a robust and reliable weatherproof connection, reduces manufacturing costs, and eliminates the need for torque-measuring wrenches, thereby preventing water damage to electronic components.
Implementation Method 1
compressing the gasket between the nut and the enclosure bushing using hand-applied force
Data Source
AI summary
A system includes a housing (105) that includes one or more ports (113) through which electrical connections to one or more electronic components situated within the housing can be made from exterior of the housing. At least one enclosure bushing (204) is coupled to at least one port. The enclosure bushing includes a cylindrical service jacket receiver (207) defining a lumen (208), a flange (212) abutting a portion of the housing, and one or more lugs (216,217,302,303) extending from a portion of the cylindrical service jacket receiver. A coupling nut (205) having one or more circumferential lug receivers (702,703,704,805) applies a compression force to the frustoconical weather gasket when the one or more lugs engaging the locking notch (708) of the one or more circumferential lug receivers.