Watertight Electrical Backshell for Underground Meter Connectors

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Solution Overview

Problem

Underground smart utility meters face challenges in maintaining a robust and reliable watertight connection between telemetry devices and the meter due to exposure to pressures and water, which can compromise the integrity of electrical connections.

Innovation Solution

An electrical backshell with a flexible strain relief and integral cylindrical portion, coupled with a coupling nut, provides a waterproof seal for electrical connectors in underground utility meter boxes by eliminating potential leak paths through the cable and connector interface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a standard electrical connector is used in an underground meter box, then the device can perform data transmission functions, but the connection becomes vulnerable to water exposure and ground movement

Engineering Contradiction:

Improveconnection reliabilityVSAvoidwater exposure and movement vulnerability

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The connector system is divided into separate functional components: a base connector mounted on the PCB, a strain relief assembly with sealing elements, and a coupling nut. This segmentation allows each component to address specific protection needs independently while working together as a complete waterproof system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A strain relief assembly with integrated sealing elements acts as an intermediary between the electrical connector and the cable. This intermediary component provides the waterproof barrier and mechanical protection, separating the electrical function from the environmental protection function.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If the meter box is installed in harsh underground environments, then the system can operate in field conditions, but the electrical connections become vulnerable to pressures and water exposure

Engineering Contradiction:

Improveenvironmental adaptabilityVSAvoidpressures and water exposure

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The strain relief incorporates flexible sealing elements including an O-ring and a flexible membrane that can deform to accommodate cable movements and pressure changes while maintaining the waterproof barrier. These flexible components allow the connector to adapt to environmental variations without compromising sealing integrity.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The strain relief assembly is designed to absorb and cushion against external pressures and movements before they can reach the electrical connector. The flexible neck and sealing elements provide preemptive protection against water ingress and mechanical stress from ground movement or heavy equipment.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Object-affected harmful factors

If a waterproof seal is added to the connector, then water protection is improved, but the device complexity increases

Engineering Contradiction:

Improvewater protectionVSAvoidconnector structure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The strain relief, sealing elements (O-ring and flexible membrane), and cable management features are merged into a single integrated assembly that attaches to the base connector. This consolidation provides comprehensive waterproof protection while minimizing the number of separate components and assembly steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The strain relief assembly serves multiple functions simultaneously: it provides waterproof sealing, mechanical strain relief, cable management, and pressure protection. This multi-functionality reduces the need for additional specialized components, thereby limiting the increase in overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 ensures a reliable watertight seal, maintaining functionality in harsh environments up to 30 meters underwater, enhancing the durability and reliability of electrical connections in rugged field conditions.

Implementation Method 1

a coupling nut configured to connect with the base connector engages both the strain relief and the base connector to bring the cylindrical portion of the strain relief into sealing engagement with the base connector. When the coupling nut is tightened, the backshell provides waterproof protection

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS12506295B2Watertight electrical backshell for sealing electrical connectors in an underground utility meter box

Publication Date: 2025.12.23 NICOR INC

AI summary

An electrical backshell that includes a strain relief having a flexible neck connected to a jacketed data cable proximate a terminal end of the data cable, and a cylindrical portion integral with said flexible neck; a base connector configured to accept and accommodate the terminal end of the data cable; a coupling nut configured to connect with said base connector and to engage said strain relief and to bring said cylindrical portion of said strain relief into sealing engagement with said base connector, wherein when assembled, said electrical backshell provides waterproof protection for electrical connectors in underground utility meter boxes.