Connector separation resistance mechanism

Abstract

The plug connector (100) includes a housing (110) having a cable opening (105) for receiving a cable with multiple wires. A plurality of contacts (150) are disposed within a contact insert (130). Retaining pins (160, 180, 190) are disposed within the contact insert, each having a base (163) and a protruding portion (161). The protruding portion (161) is configured to engage with a socket insert (230) of a socket connector (200) through a socket contact opening (235) when the plug connector (100) is inserted into the socket connector (200). The diameter of the protruding portion (161) of the retaining pins (160, 180, 190) exceeds the diameter of the socket contact opening (235). The retaining pins (160, 180, 190) elastically deform when the plug connector (100) is inserted into or removed from the socket connector (200), thereby increasing the extraction force.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 63 / 446,962, filed February 20, 2023, the entire contents of which are incorporated by reference.

[0002] The present disclosure relates to electrical connectors, and more particularly to plug connectors having mechanisms for increasing withdrawal resistance.

[0003] Background technology A plug and socket connector typically consists of a male plug and a female socket. The plug typically contains pin contacts, and the socket typically contains receptacle contacts. The socket is often permanently fixed to the device, such as a chassis connector, while the plug is attached to a cable. Both the plug and socket may be connected to a cable, for example, to connect two cables together.

[0004] A plug typically has one or more metal contacts, also called terminals, that are inserted into openings in the mating socket. The connection between the mating metal parts must be tight enough to make a good electrical connection and complete the circuit.

[0005] A locking mechanism may be used to mechanically lock the plug into the socket. The locking mechanism can be opened to disengage the plug from the socket. Technical standards such as UL 1682 require that even when the locking mechanism is disengaged, the minimum withdrawal force must be sufficient to prevent unintentional withdrawal of the plug from the socket during normal use. The withdrawal force is typically determined by the friction of the mating contacts.

[0006] Summary of the Invention In some aspects, the technology described herein relates to a plug connector. The plug connector includes a housing having a cable opening for receiving a cable with multiple wires. A plurality of contacts are disposed within a contact insert. A retention pin is disposed within the contact insert. The retention pin has a base and a protruding portion. The protruding portion of the retention pin is configured to engage with a socket insert of a socket connector through the socket contact opening when the plug connector is inserted into the socket connector. The diameter of the protruding portion of the retention pin exceeds the diameter of the socket contact opening. The retention pin is configured to elastically deform when the plug connector is inserted into or removed from the socket connector. This allows the retention pin to generate a retention force when the plug connector is removed from the socket connector. This can prevent undesired release of the plug connector from the socket connector that would otherwise occur. The retention pin can take the place of a contact, thus allowing existing connectors to be retrofitted with increased retention force without requiring additional mechanical modifications.

[0007] The retaining pin may include a chamfered flange. The protruding portion of the retaining pin may include a bulging portion located proximal to the tip of the retaining pin and a generally cylindrical portion located between the bulging portion and the base. A slot may extend across the retaining pin at the bulging portion. The length of the slot may be 40% to 60% of the length of the first type of retaining pin, or 60% to 85% of the length of the second type of retaining pin. The geometries of the bulging portion and the slot cooperate to achieve a desired force-transfer relationship as the retaining pin slides in and out of the socket connector. The force-transfer relationship can be selected so that the plug connector as a whole meets a specific minimum disengagement force-transfer requirement.

[0008] The bulging portion of the retaining pin may include circumferentially spaced bulges located on either side of the slot. Each of the circumferentially spaced bulges may include a forwardly angled portion extending from a forward end of the bulge proximal to the tip of the retaining pin to a maximum diameter region of the bulge. A rearwardly angled portion may extend from the maximum diameter region of the bulge toward a rearward end of the bulge proximal to the generally cylindrical portion. In some configurations, the forwardly angled portion is longer than the rearwardly angled portion. In other configurations, the forwardly angled portion and the rearwardly angled portion have symmetrical profiles.

[0009] In some configurations, the bulge has a generally triangular profile. In other configurations, the bulge has a generally arcuate profile. In yet another configuration, the central bore may extend along the longitudinal axis through the retaining pin.

[0010] The retaining pin may be disposed within the contact insert within a space configured to accommodate one of the plurality of contacts. The retaining pin is not electrically connected to any wire.

[0011] In some aspects, the technology described herein relates to a method for assembling a plug connector, the method including the steps of guiding a cable through a cable opening in a plug connector housing, connecting contacts to wires of the cable, inserting the contacts into contact inserts, inserting a retaining pin into the contact insert, and securing the contact insert within the plug connector housing.

[0012] The method may further include selecting a retention pin from a plurality of different retention pins to selectively increase the withdrawal force required to disconnect the plug connector from the socket connector.When inserting the plug connector into the socket connector, the method includes resiliently deforming the retention pin while forcing the retention pin through an opening in a socket contact insert of the socket connector.

[0013] The following detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description. [Brief explanation of the drawings]

[0014] [Figure 1] FIG. 1 is an exploded view of a plug and socket connection system. [Figure 2] FIG. 1 is a perspective view of a plug and socket connection system. [Figure 3] FIG. [Figure 4] 3 shows the connection system of FIG. 2 without the connector housing. [Figure 5] FIG. 5 is an internal view of the assembly of FIG. 4. [Figure 6] FIG. 3 is a perspective cross-sectional view of the connection system of FIG. 2. [Figure 7] FIG. 10 is a side view showing a first configuration of the holding pin. [Figure 8] FIG. 8 is a cross-sectional view of the retaining pin of FIG. 7. [Figure 9] FIG. 8 is a perspective view of the retaining pin of FIG. 7. [Figure 10] FIG. 10 is a side view showing a second configuration of the holding pin. [Figure 11] FIG. 11 is a cross-sectional view of the retaining pin of FIG. 10. [Figure 12] FIG. 11 is a perspective view of the retaining pin of FIG. 10. [Figure 13] FIG. 10 is a side view showing a third configuration of the holding pin. [Figure 14] FIG. 14 is a cross-sectional view of the retaining pin of FIG. 13. [Figure 15] FIG. 14 is a perspective view of the retaining pin of FIG. 13. [Figure 16] FIG. 10 is a diagram showing a comparison between a pin terminal and a holding pin.

[0015] MODE FOR CARRYING OUT THE INVENTION 1 shows an exploded view of a plug and socket connection system. The system includes a plug connector 100 and a socket connector 200.

[0016] The plug connector 100 includes a plurality of pin contacts 150. The pin contacts are sometimes referred to as male contacts. In the context of this application, these terms should be understood more broadly to refer to the first type of contact. Each of the pin contacts 150 is electrically connected to one wire of a cable during use. The contacts may be in the form of a screw terminal, a crimp terminal, or a cage-clamp terminal. The terms contact and terminal are used interchangeably. The pin contacts 150 are securely held within a plug insert 130. The plug insert 130 is secured within a plug housing 110. The plug housing 110 may also be referred to as a hood. The plug housing 110 includes a cable entry opening 105 that can be positioned for rear or side cable entry. A cable entry protector 120 may be secured to the cable entry opening 105. The cable entry protector 120 may have a variety of configurations. For example, the cable entry protector 120 may be a universal cable gland, a special cable clamp with strain relief, a cable attachment with a bell mouth, or a kink prevention device. The cable gland may include one or more seals.

[0017] The plug connector 100 is configured to mate with a corresponding socket connector 200. The socket connector 200 includes a plurality of receptacle contacts 250. The receptacle contacts are sometimes referred to as female contacts. In the context of this application, they should be more broadly understood to refer to the second type of contact. Each of the receptacle contacts 250 is configured to receive one of the pin contacts 150 to form an electrical connection. The receptacle contacts 250 are securely held within a socket insert 230. The socket insert 230 is fixed within the socket housing 210.

[0018] The geometries of the plug insert 130 and the socket insert 230 are adjusted so that they can be plugged into one another. When plugged into one another, portions of the plug insert 130 and the socket insert 230 overlap.

[0019] A locking mechanism may be provided to lock the plug connector 100 to the socket connector 200. The locking mechanism may include a lever 211 pivotally connected to the socket housing 210. The lever 211 may include a recess that engages with the locking protrusion 111 of the plug housing 110. When engaged, the lever securely holds the plug connector 100 and the socket connector 200 together. The lever 211 can be pivoted to an unlocked position to disengage the locking protrusion 111 for removing the plug connector 100 from the socket connector 200.

[0020] FIG. 1 illustrates an example in which the socket connector 200 is suitable for permanently securing to a device, such as a chassis connector. FIG. 2 illustrates an alternative configuration in which the plug housing 110 and socket housing 210 are similar and are both configured to connect to respective cables. Both the plug housing 110 and the socket housing 210 include respective cable entry openings 105, 205. The plug housing 110 is locked to the socket housing 210 by a locking mechanism. The locking mechanism here includes two levers 211, 212. The levers 211, 212 are shown in a locked position. To unlock the plug housing 110 from the socket housing 210, the levers can be pivoted toward the socket connector 200. A seal 203 is disposed between the plug housing 110 and the socket housing 210.

[0021] Once the locking mechanism is unlocked, the plug connector 100 and socket connector 200 can be disconnected by applying an axial pull-out force. The amount of pull-out force required to separate the plug connector 100 from the socket connector 200 depends primarily on the number and friction between the pin contacts 150 and receptacle contacts 250 in the connectors. The pull-out force can further depend on the friction between the plug insert 130 and socket insert 230 if they are designed with an interference fit.

[0022] In some applications, the withdrawal force required to remove plug connector 100 from socket connector 200 may be less than the desired retention force of the plug connector. That is, by pulling plug connector 100 with a withdrawal force less than the desired retention force, plug connector 100 can be removed from socket connector 200. This is particularly problematic when the withdrawal force is less than the retention force required by standards such as UL 1682.

[0023] The UL 1682 standard requires a minimum retention force of 67 N for connectors rated at 60 A. Therefore, a withdrawal force of at least 67 N but no more than 111 N may be desirable. Furthermore, the withdrawal force caused by existing friction between the contacts 150, 250 and possibly the contact insert 130, 230 may be less than the desired minimum of 67 N. In that case, the retention pin 160 may be inserted into an unused contact cavity 131 of the plug insert 130.

[0024] 3 is a perspective view of the plug connector 100 as seen from the plug-in side. A plug insert 130 is disposed within the plug connector 100. The plug insert 130 includes six identical contact cavities 131 arranged in a 2x3 matrix. The plug insert 130 is modularly designed using three pairs of identical insert modules 132, each with two contact cavities 131. The plug insert 130 is equipped with five pin contacts 150. A retaining pin 160 is disposed in the central contact cavity 131 of the insert module 132.

[0025] Figure 4 shows the connection system of Figure 2 without the connector housings 110, 210. The plug insert 130 includes an insert frame 133 to which three identical plug insertion modules 132 are attached. Similarly, the socket insert 230 includes an insert frame 233 to which three socket insertion modules 232 are attached. The insert frame 133 of the plug connector 100 and the insert frame 233 of the socket connector 200 may be identical. However, the plug insertion modules 132 of the plug connector 100 and the socket insertion modules 232 of the socket connector 200 are complementary and configured to be plugged into each other. A portion of the plug insertion module 132 overlaps a portion of the socket insertion module 232 when plugged into each other.

[0026] Figure 5 shows the assembly of Figure 4 with additional parts removed to reveal the interior of the connection system. In the plugged-in state shown, pin contacts 150 are received in receptacle contacts 250. Each contact includes a mating portion 151, 251 and an opposing connecting portion 153, 253. The mating portion 251 of the receptacle contact 250 is configured to receive the mating portion 151 of the pin contact 150. Each connecting portion 153, 253 is generally hollow cylindrical and configured to receive a wire. The wire may be connected to the contacts 150, 250 by crimping.

[0027] The contact flanges 152, 252 are in each case arranged between the mating portion 151, 251 and the connecting portion 153, 253 of the respective contact. The insert module 132 includes resilient locking arms 134 that engage behind the contact flanges 152, 252 and hold the contacts in place. In particular, the resilient locking arms 134 prevent the contacts 150, 250 from being pushed out of the plug insert 130, 230 in the opposite direction to the plug-in direction.

[0028] Retaining pin 160 seats in the same contact cavity occupied by pin contact 150. Like pin contact 150, retaining pin 160 includes a flange 162. Unlike pin contact 150, retaining pin 160 does not have a connecting portion 153; that is, retaining pin 160 is not connected to any wire. Flange 162 forms the rear end of retaining pin 160.

[0029] Figure 6 shows a perspective cross-sectional view of the connection system of Figure 2 as indicated by arrow 6 in Figure 5. The cross-section shows the retaining pin 160 seated within the plug insert 130. The protruding portion 161 of the retaining pin 160 extends through the socket contact opening 235 into the socket insert 230. In the plugged-in state, the protruding portion 161 of the retaining pin 160 is located in the overlapping area of ​​the plug insert 130 and the socket insert 230.

[0030] The diameter of the protruding portion 161 of the retention pin 160 exceeds the diameter of the socket contact opening 235. The retention pin 160 elastically deforms when the plug connector 100 is inserted into or removed from the socket connector 200. Thus, the retention pin 160 creates an additional retention force that must be overcome when separating the plug connector 100 from the socket connector 200.

[0031] The additional retention force provided by the retaining pin 160 depends on its shape as well as the material from which it is made. Thus, by selecting one of several different designs of retaining pin 160, it is possible to tailor the retention force of the entire connector system.

[0032] 7-15 show three such different designs of retention pins 160, 180, and 190 that generate different retention forces. Retention pin 160 includes a protruding portion 161 and a base 163. Protruding portion 161 engages with socket insert 230 of socket connector 200. Base 163 is firmly held within plug insert 130 by its chamfered flange 162.

[0033] The design shown in Figures 7-9 illustrates a protruding portion 161 having a bulging portion 164 located proximal to the tip 166 of the retaining pin 160. A generally cylindrical portion 165 is located between the bulging portion 164 and the base 163. A slot 167 extends across the retaining pin within the bulging portion 164 and partially into the generally cylindrical portion 165. The length of the slot 167 is directly related to the resilience of the retaining pin 160 and, thereby, the retention force generated by the retaining pin 160. Figures 7-9 illustrate a configuration utilizing a long slot 167 having a length between 60% and 85% of the overall length of the retaining pin 160. Figures 10-12 illustrate a configuration utilizing a short slot 187 having a length between 40% and 60% of the overall length of the retaining pin 180. The length of the slots 167, 187 can be varied to fine-tune the retention force generated by the retaining pins 160, 180.

[0034] The bulging portion 164 includes circumferentially spaced bulges 170. The circumferentially spaced bulges are located on either side of the slot 167. Although Figures 7-8 show two bulges 170, three or more bulges 170 can be used. For example, the retaining pin 160 can be designed to utilize two intersecting slots 167 and four bulges 170.

[0035] Each of the circumferentially spaced bulges 170 includes a forwardly tapered portion 171 that extends from a front end of the bulge 170 proximal to the tip 166 of the retaining pin 160 to a maximum diameter region 173 of the bulge 170. The width mw of the retaining pin 160 at the maximum diameter region 173 is greater than the socket contact opening 235. For example, the diameter of the socket contact opening 235 may be 6.25 mm. The width mw of the retaining pin 160 at the maximum diameter region 173 of the bulge 170 may be 6.9 mm. That is, the maximum diameter region 173 is approximately 10% wider than the socket contact opening 235. Here, approximately 10% refers to a width between 5% and 15% wider.

[0036] 7-9, forward angled portion 171 of bulge 170 is longer than rearward angled portion 172. The asymmetry causes a different force profile and corresponding user perception when inserting plug connector 100 into socket connector 200 compared to removing plug connector 100 from socket connector 200. The resistance force when inserting plug connector 100 into socket connector 200 increases slowly, while the pull-out force resisting removal of plug connector 100 from socket connector 200 increases sharply with minimal movement.

[0037] The forward sloping portion 171 of the bulge 170 may be in the shape of a frusto-conical sector having a cone angle of 5° to 15°, particularly about 8°. The rearward sloping portion 172 of the bulge 170 may be in the shape of a frusto-conical sector having a steeper cone angle of 30° to 65°, particularly about 50°. The different cone angles allow the total insertion force to insert the plug connector 100 into the socket connector 200 to be lower than the total withdrawal force to remove the plug connector 100 from the socket connector 200.

[0038] 10-12 show an alternative design in which the first sensory effect during insertion of plug connector 100 into socket connector 200 and the second sensory effect during removal of plug connector 100 from socket connector 200 are the same. This is achieved by the symmetrical arched profile 182 of bulge 181 of retention pin 180, as shown in FIG. 11. The symmetrical arched profile 182 changes the force-displacement curve of retention pin 180 compared to the triangular asymmetric profile of bulge 170 shown in FIG. 8.

[0039] 13-15 show yet another alternative design for a retaining pin 190. The retaining pin 190 is rotationally symmetric and includes a central bore 191. A single bulge 192 extends completely around the retaining pin 190. The single bulge 192 has an arched outer profile.

[0040] Although the drawings show the retaining pin 160 in the plug connector 100 adjacent to the pin contact 150, it should be understood that the retaining pin 160 can equally be used adjacent to the receptacle contact 250 in the socket connector 200.

[0041] For comparison, FIG. 16 shows a retaining pin 160 directly adjacent to the pin contact 150. The axial length of the retaining pin 160 is clearly shorter than the axial length of the pin contact 150. The retaining pin 160 is not provided with a connection portion 153 for connecting a wire. This makes the retaining pin 160 easier and cheaper to manufacture than the pin contact 150. The diameter of the substantially cylindrical portion 165 of the retaining pin 160 corresponds to the diameter of the mating portion 151 of the pin contact 150. The maximum width mw of the bulging portion 164 of the retaining pin 160 is 10 to 20%, approximately 15%, larger than the diameter of the substantially cylindrical portion 165.

[0042] The retaining pin 160 can be manufactured as a machined metal part, for example from an aluminum cylinder. The retaining pin 160 does not need to be conductive and can be made of plastic, for example in the form of an injection molded plastic part.

[0043] The retention pin 160 may be located in the same space within the plug connector 100 that may be occupied by the pin contact 150. Alternatively, the retention pin 160 may be located in the same space within the socket connector 200 that may be occupied by the receptacle contact 250. Multiple retention pins 160 may be used in a given plug connector 100 or socket connector 200.

[0044] The use of retention pins can be particularly advantageous when existing connection systems must meet retention force requirements for which they were not originally designed. In such instances, retention pins can be used to retrofit existing connectors if the connector can accommodate more pins than are needed for a given application. In these instances, a method for assembling a plug connector can be used. The method includes the steps of guiding a cable through a cable opening in a plug connector housing, connecting contacts to wires of the cable, inserting the contacts into contact inserts, inserting retention pins into the contact inserts, and securing the contact inserts within the plug connector housing.

[0045] More than one type of retention pin can be used to tune an existing connector to a given extraction force, in which case the method includes selecting a retention pin from a plurality of different retention pins to selectively increase the extraction force required to unseat the plug connector from the socket connector.

[0046] The increased withdrawal force is caused by elastic deformation of the retaining pin when the plug connector is inserted into the socket connector, and therefore the method includes elastically deforming the retaining pin while forcing it through an opening in a socket contact insert of the socket connector.

[0047] While the present invention has been described with reference to exemplary embodiments, it will be readily apparent to those skilled in the art that the invention is not limited to the disclosed or illustrated embodiments, but on the contrary, is intended to encompass many other modifications, substitutions, variations, and a wide range of equivalent arrangements that are included within the spirit and scope of the appended claims.

Claims

1. A plug connector (100) a housing (110) having a cable opening (105) for receiving a cable having a plurality of wires; a contact insert (130); a plurality of contacts (150) disposed within the contact insert (130); A retaining pin (160, 180, 190) disposed within the contact insert, the retaining pin (160, 180, 190) comprising: a base (163); a protruding portion (161); a retaining pin (160, 180, 190) having Equipped with the protruding portion (161) of the retaining pin (160, 180, 190) is configured to engage with a socket insert (230) of the socket connector (200) through a socket contact opening (235) when the plug connector (100) is plugged into the socket connector (200); The diameter of the protruding portion (161) of the retaining pin (160, 180, 190) exceeds the diameter of the socket contact opening (235). A plug connector (100).

2. The retaining pins (160, 180, 190) are configured to elastically deform when the plug connector (100) is inserted into or removed from the socket connector (200). The plug connector (100) of claim 1.

3. The retention pins (160, 180, 190) provide a retention force when the plug connector (100) is removed from the socket connector (200). The plug connector (100) of claim 1.

4. the base (163) of the retaining pin (160) includes a chamfered flange (162); The protruding portion (161) a bulge (164) located proximal to the tip (166) of said retaining pin (160); a generally cylindrical portion (165) disposed between said bulging portion (164) and said base portion (163); Including, The plug connector (100) of claim 1.

5. A slot (167) extends across the retaining pin (160) within the bulge portion (164); The plug connector (100) of claim 4.

6. the slot (167) extends from the tip (166) into the generally cylindrical portion (165); The length of the slot (167) is 40% to 60% of the length of the retaining pin (160); The plug connector (100) of claim 5.

7. the slot (167) extends from the tip (166) into the generally cylindrical portion (165); The length of the slot (167) is 60% to 85% of the length of the retaining pin (160); The plug connector (100) of claim 5.

8. the swelling portion (164) includes circumferentially spaced bulges (170); said circumferentially spaced bulges (181) being disposed on either side of said slot (167); The plug connector (100) of claim 5.

9. Each of the circumferentially spaced bulges (170, 181) a forwardly tapered portion (171) extending from a front end of the bulge (170) proximal to the tip (166) of the retaining pin (160) to a maximum diameter region (173) of the bulge (170); a rearwardly tapered portion (172) extending from the maximum diameter region (173) of the bulge (170) toward the rear end of the bulge (170) proximal to the generally cylindrical portion (165); Equipped with The plug connector (100) of claim 8.

10. The forward sloped portion (171) is longer than the rearward sloped portion (172). The plug connector (100) of claim 9.

11. the forward sloped portion (171) and the rearward sloped portion (172) have symmetrical profiles; The plug connector (100) of claim 9.

12. the bulge (170) has a generally triangular profile; The plug connector (100) of claim 9.

13. the bulge (181) has a generally arcuate profile; The plug connector (100) of claim 9.

14. A central bore (191) extends through said retaining pin (190) along the longitudinal axis; The plug connector (100) of claim 4.

15. A method for assembling a plug connector (100), comprising: Guiding the cable through a cable opening (105) in the plug connector housing (110); connecting contacts (150) to wires of said cable; Inserting the contact (150) into a contact insert; Inserting a retaining pin (160, 180, 190) into the contact insert (130); Fixing the contact insert (130) within the plug connector housing (110); A method comprising:

16. Selecting the retention pins (160, 180, 190) from a plurality of different retention pins (160, 180, 190) to selectively increase the pull-out force required to disconnect the plug connector (100) from the socket connector (200).

16. The method of claim 15, further comprising:

17. The method comprises: Inserting the plug connector (100) into the socket connector (200) further comprising The step of inserting the plug connector (100) into the socket connector (200) includes a step of elastically deforming the retaining pins (160, 180, 190) while pushing the retaining pins (160, 180, 190) through openings (235) in socket contact inserts (230) of the socket connector (200).

16. The method of claim 15.

18. A plug connector (100) a housing (110) having a cable opening (105) for receiving a cable having a plurality of wires; a contact insert (130); a plurality of contacts (150) disposed within the contact insert (130); A retaining pin (160, 180, 190) disposed within the contact insert, the retaining pin (160, 180, 190) comprising: a base (163); a protruding portion (161); a retaining pin (160, 180, 190) having Equipped with the protruding portion (161) of the retaining pin (160, 180, 190) is configured to engage with the socket connector (200) when the plug connector (100) is inserted into the socket connector (200); the retaining pin (160, 180, 190) is disposed within the contact insert (130) within a space configured to receive one of the plurality of contacts (150); The retaining pins (160, 180, 190) are not electrically connected to any wires; A plug connector (100).

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