Cable-Mountable Connector With Removable Contacts
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Solution Overview
Problem
Existing cable-mounted electrical connectors are not removable, making it necessary to discard the entire connector if a cable or contact is damaged, which is inefficient and costly, especially in harsh environments where maintenance is required.
Innovation Solution
A cable-mountable connector design featuring a shell with a contact housing and deflectable finger clips that allow for removably securing electrical contacts, enabling individual contacts and cables to be replaced without replacing the entire connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If epoxy is poured into the back cavity to permanently lock contacts, then reliability of connection is improved, but ease of repair deteriorates
Solution Approach 1:
The connector is divided into separable components: the housing, the contact assembly, and the cable assembly. The contact assembly can be independently removed from the housing by actuating the release mechanism, allowing repair without replacing the entire connector or damaging the housing structure.
Solution Approach 2:
The connector transitions from a static permanent bond (epoxy) to a dynamic reversible connection. The release mechanism allows the contact assembly to be securely held during normal operation but can be deliberately disengaged when repair is needed, providing conditional stability.
2Reliability
If entire connector is discarded when contact is damaged, then reliability is maintained, but loss of substance increases
Solution Approach 1:
Instead of discarding the entire connector when a contact is damaged, the invention enables selective discarding of only the faulty contact assembly. The housing and functional contacts are recovered and retained for continued use, minimizing material waste while maintaining system reliability.
Solution Approach 2:
The connector is segmented into replaceable contact assemblies and a reusable housing. This segmentation allows the valuable housing structure to be separated from the disposable contact components, enabling partial replacement rather than total disposal.
3Reliability
If contacts are permanently secured, then reliability is improved, but adaptability deteriorates
Solution Approach 1:
The connector provides dynamic adaptability through its release mechanism. During normal operation, contacts are securely held for reliable performance. When reconfiguration is needed, the release mechanism enables easy removal and reinstallation of contact assemblies in different configurations or with different cable types.
Solution Approach 2:
The housing and contact assembly design allows the same connector body to accommodate different types of contacts and cables. The standardized interface and release mechanism enable the connector to be adapted for various applications and configurations without requiring different housing designs.
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 allows for field servicing and customization of the connector, reducing waste and maintenance costs by enabling the replacement of damaged contacts and cables, while maintaining reliable signal transmission in harsh environments.
Implementation Method 1
the finger clips having deflectable latches, wherein the contact cavities of the contact housing are configured to removably receive electrical contacts therein through the rear end, the deflectable latch of the finger clip in the corresponding contact cavity configured to engage a retention shoulder of the electrical contact
Data Source
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AI summary
A connector (101) for a cable assembly (100) includes a shell (102), a contact housing (110), and multiple finger clips (134). The contact housing is held in a chamber (116) of the shell. The contact housing defines contact cavities (114) extending through the contact housing between front and rear ends (126, 128) thereof. The finger clips are held in the contact cavities of the contact housing. The finger clips have deflectable latches (136). The contact cavities of the contact housing are configured to removably receive electrical contacts (112) therein through the rear end. The deflectable latch of the finger clip in the corresponding contact cavity is configured to engage a retention shoulder (168) of the electrical contact to removably secure the electrical contact in the contact cavity. The electrical contacts held in the contact housing are configured to mate with corresponding mating contacts of a mating connector.