Asymmetric Plug Connector Tolerance Compensation
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Solution Overview
Problem
Existing connectors for insulating glass construction have limited tolerance compensation, leading to variable contact pressure and instability when connecting spacer hollow profiles, especially with large tolerances, resulting in inconsistent holding force and potential wobbling.
Innovation Solution
The connector design features one leg shorter and the other leg longer, with inclined and tapered holding elements that adapt to different profile dimensions, ensuring consistent contact pressure and improved rigidity, along with beveled ends and elastic compensating elements to secure the connector in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If both legs extend over the entire height of the connector, then the connector achieves high rigidity and structural stability, but the tolerance compensation capability deteriorates and contact pressure becomes inconsistent
Solution Approach 1:
The connector employs asymmetric leg design where one leg extends over the entire height while the other leg is shortened. This asymmetry creates differential flexibility: the full-height leg provides structural rigidity and stability, while the shortened leg offers tolerance compensation capability, allowing the connector to adapt to varying spacer hollow profile dimensions and maintain consistent contact pressure across different tolerance ranges.
Solution Approach 2:
Different regions of the connector are given different mechanical properties through the asymmetric leg design. The full-height leg region provides high rigidity and stability, while the shortened leg region provides flexibility and tolerance compensation. This local differentiation of mechanical properties allows the connector to simultaneously achieve both rigidity and adaptability.
2Device complexity
If holding elements are vertical, then the connector structure is simple, but insertion difficulty increases and holding force decreases
Solution Approach 1:
Instead of making the holding elements inclined to improve insertion ease (which would increase complexity), the invention maintains simple vertical holding elements and instead inverts the approach by using asymmetric leg lengths to create the necessary insertion facilitation. The shortened leg acts as a guide that automatically aligns and facilitates insertion, while the vertical holding elements maintain structural simplicity.
3Ease of operation
If holding elements are inclined, then insertion ease improves, but structural complexity increases
Solution Approach 1:
The asymmetric leg design inherently provides insertion facilitation through the shortened leg acting as a guide, eliminating the need for inclined holding elements. This maintains the simplicity of the holding element configuration while achieving ease of insertion through the overall asymmetric geometry of the connector body.
4Ease of manufacture
If both legs are of equal length, then manufacturing is simple, but tolerance compensation capability deteriorates
Solution Approach 1:
The connector uses asymmetric leg lengths (one full-height, one shortened) to provide tolerance compensation capability. While this requires slightly more complex manufacturing compared to equal-length legs, the design simplifies the overall assembly process and improves adaptability to different spacer hollow profile dimensions, making it more versatile in application.
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 achieves a consistent holding force across a wide tolerance range, enhanced resistance to torsional loads, and secure seating within the hollow profile, while facilitating easy insertion and preventing accidental removal.
Implementation Method 1
the holding and compensating elements are designed to taper, starting from their base. With such a shape, the holding and compensating elements can be given the desired elasticity, as a result of which they also adapt very well to different dimensions of the hollow profile and compensate for tolerances.
Data Source
Figure 1~2
Figure 3
AI summary
The plug connector (1) has a base portion (2) and two long side edges (3,4). Two rising legs (5,6) are formed on the base portion. The base portion is joined together with the long side edges that are protruded outward. The resilient deformable slats (7) are arranged for plug-in portion and are bent or flexed at the long side edges along rear insertion direction. The retaining and compensating elements (12) are arranged in the region of the rising legs and are projected vertically to the base portion.