Angled Electrical Connector Resisting Pivoting Forces
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Solution Overview
Problem
Existing breakaway electrical connectors for cables are prone to accidental disengagement due to cable tension, and deliberate disengagement can cause excessive stress on connections, especially when mounted on flexible panels like clothing, where pivoting forces can lead to unintended release.
Innovation Solution
An angled electrical connector design with a cylindrical inner portion and a tapered outer portion is used, resisting pivoting movements while allowing disengagement only through a force along the sleeve direction, combined with a resilient coil spring and a protective collar to maintain secure engagement and prevent accidental disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a breakaway electrical connector is designed to be easily disengaged by pulling the cable, then the connector can be quickly disconnected when required, but cable tension can lead to accidental disengagement
Solution Approach 1:
The connector is divided into two functional parts: a male connector with a resilient member for easy disengagement, and a female connector with a retaining structure for stable engagement. The resilient member can be actuated to release the connection, while the female connector's structure prevents accidental release from cable tension alone.
Solution Approach 2:
The resilient member in the male connector provides dynamic response to applied forces. When a deliberate pulling force is applied, the resilient member deforms to enable disengagement. However, normal cable tension during use is insufficient to deform the resilient member, maintaining connection stability during operation.
2Ease of operation
If the connector allows disengagement by pivoting the cable, then it is convenient to disconnect when mounted on panels, but pivoting forces can cause accidental disengagement on flexible substrates like clothing
Solution Approach 1:
The connector design creates asymmetric force requirements: deliberate disengagement requires a specific pulling motion along the cable axis that actuates the resilient member, while pivoting motions in other directions are resisted by the engagement geometry. This ensures that accidental pivoting on flexible substrates cannot release the connection.
Solution Approach 2:
The engagement structure is designed so that the same geometric features that enable easy deliberate disengagement also provide resistance to unintended pivoting forces. The resilient member's deformation path is designed to require axial pulling rather than lateral pivoting, converting potential harmful pivoting forces into beneficial engagement stability.
3Strength
If a resilient member is used to maintain engagement, then the connector can be firmly engaged, but the resilient member may deform under tension and cause accidental disengagement
Solution Approach 1:
The resilient member is designed with specific local properties: it provides strong engagement force through its elastic deformation characteristics, but its geometry and material selection ensure that the force required to deform it beyond the engagement state is significantly higher than normal cable tension. This creates a threshold effect where normal use tension maintains engagement while deliberate strong pulling releases it.
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
This design enhances the security of electrical connections on flexible substrates by preventing accidental disengagement due to tension or pivoting forces, ensuring a stable and reliable connection even under movement and potential snagging or contact with objects.
Implementation Method 1
an inward thrust of the plug into the receptacle of the mating connector will expand the coil spring to enable the spring to snap into the annular groove formed in the plug
Implementation Method 2
The forward tip of the plug is tapered to exert a cam action, whereby an inward thrust of the plug into the receptacle of the mating connector will expand the coil spring
Data Source
AI summary
An angled electrical connector has a body having an engagement portion including a sleeve which extends in a longitudinal first direction for engaging with a mating electrical connector. The sleeve has a cylindrical inner portion at the base of the sleeve and a tapered portion, such that the opening of the sleeve is larger than the base. A corresponding receptacle part is also provided, having a projecting connection port, with a corresponding cylindrical portion at or near the end.