Waterproof Electrical Junction System with Composite Seal
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Solution Overview
Problem
Conventional electrical junction systems in water-related environments, such as septic tanks, are prone to contamination from water and debris, leading to electrical shorts and corrosion due to inadequate sealing, even when positioned above the fluid level.
Innovation Solution
A water impermeable electrical junction system featuring a base with seal members and connectors that prevent contaminants from entering by using a combination of first and second seal members and connectors, which are designed to cover and protect the electrical connections from liquids and debris.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional junction boxes are positioned above the fluid level in the tank, then the electrical connections are protected from direct submersion, but they are still prone to splashing or accidental rising of fluid level which exposes the electrical connections to water
Solution Approach 1:
The patent employs a waterproof seal assembly comprising a seal member that forms a flexible barrier between the interior and exterior environments of the junction box. This seal member extends into the tank interior and creates a water-tight boundary, effectively preventing water and contaminants from reaching electrical connections even when fluid levels rise or splashing occurs.
2Reliability
If electrical connections are sealed to prevent water contact, then protection from contamination is improved, but over time seals degrade and become increasingly susceptible to random contact with contaminants
Solution Approach 1:
The seal member is constructed from composite materials including a fluoropolymer outer layer and an inner layer comprising a copolymer blend. This multi-layer composite structure provides superior resistance to degradation from chemicals, UV exposure, and physical wear, significantly extending the service life of the seal while maintaining its waterproofing effectiveness.
Solution Approach 2:
The design incorporates a seal member with enhanced durability properties that anticipates and resists degradation from environmental factors such as UV radiation, chemicals, and physical stress. The copolymer blend is specifically selected for its resistance to these degrading factors, providing long-term protection before failure can occur.
3Reliability
If a waterproof seal assembly is added to the junction box, then protection from water and debris is improved, but the device complexity increases
Solution Approach 1:
The waterproof seal assembly is designed as a separate, extractable component that can be installed and removed independently from the main junction box structure. This modular approach allows the seal to be replaced without disassembling the entire junction box, thereby minimizing the increase in operational complexity while maintaining superior protection.
Data Source
AI summary
A water impermeable electrical junction system for effectively preventing a contaminant such as liquid, water, and debris from contacting electrical connections. The water impermeable electrical junction system generally includes a base, a first seal member connected to the base, a first connector positioned within the first seal member, a second seal member configured and arranged to operatively connect to the first seal member, and a second connector positioned within the second seal member. The first connector and the second connector electrically connect to one another with the first seal member and second seal member covering the first connector and second connector to prevent the entry of a contaminant inside of the seal members or to make contact with the connectors.