Wearable Electrical Connector With Open-Ended Tunnel
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Solution Overview
Problem
Existing electrical connectors face challenges with debris accumulation and moisture exposure, which can hinder operation and lead to connectivity issues, as their mating interfaces are often shrouded, making cleaning difficult and potentially damaging, and they are vulnerable to liquids and moisture.
Innovation Solution
The design features a wearable electrical connector system with a housing and shroud that includes an open-ended tunnel for easy cleaning and reduced debris trapping, along with sealing members to prevent moisture ingress, allowing for reliable mating and operation in various environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the mating interface is shrouded to protect terminals, then protection against external factors is improved, but cleaning difficulty increases and debris accumulation worsens
Solution Approach 1:
The connector is divided into separate functional zones: an exposed mating interface area for cleaning access and a shrouded tunnel area for protection. The shroud segments the protected internal space from the external environment while leaving the mating interface accessible.
Solution Approach 2:
A removable cap or cover acts as an intermediary element that can be temporarily removed to allow cleaning of the mating interface, then replaced to restore protective shielding. This mediator enables both cleaning access and protected operation.
2Object-affected harmful factors
If the mating interface is shrouded to protect terminals, then protection against external factors is improved, but vulnerability to moisture increases
Solution Approach 1:
A flexible waterproof membrane or thin film seals the tunnel opening, providing moisture protection while allowing the shroud structure to maintain its protective enclosure. The flexible film conforms to the opening and prevents liquid ingress.
Solution Approach 2:
The shroud assembly combines different materials: a rigid shroud structure for mechanical protection and a waterproof sealing material (such as rubber gasket or coated surface) for moisture resistance, creating a composite protective system.
3Object-generated harmful factors
If cleaning attempts are made on shrouded mating interfaces, then debris removal may be achieved, but terminal damage increases
Solution Approach 1:
The mating interface is extracted or removed from the shrouded protective enclosure during cleaning operations. The connector can be disassembled or the mating face exposed by removing the shroud or cap, allowing cleaning without applying force to protected terminals.
Solution Approach 2:
Protective measures are taken before cleaning: the shroud is removed or positioning features are engaged to prevent excessive cleaning force from reaching the terminals. The cleaning action is prepared and controlled to occur only on exposed surfaces.
Data Source
AI summary
A wearable connector includes a housing having a base and a shroud that extends from the base. The shroud includes a tunnel having an open end and an interior surface. The open end of the tunnel is configured to receive a mating connector therein. The base is configured to be mounted to a wearable article. Terminals are held directly by the shroud such that mating segments of the terminals extend at least one of directly on or through the interior surface of the tunnel. The tunnel of the shroud is configured to receive the mating connector into the tunnel through the open end such that the mating segments of the terminals mate with mating terminals of the mating connector within the tunnel.