Circular Plug Connector Monolithic Compression Element
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Solution Overview
Problem
Existing electrical connectors used in harsh environments, such as military and aerospace applications, require multiple retaining components to maintain a spring element in place, leading to increased complexity and cost during manufacturing and assembly.
Innovation Solution
A circular plug connector design featuring a self-supporting compression element with a spring element and integral retaining shim support, which is monolithic and compressible, allowing axial movement within the connector housing without separate retention components, thereby simplifying the assembly and reducing parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple retaining components (retaining washer and snap ring) are used to hold the spring element in place, then the spring element is securely retained within the connector housing, but the assembly complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple separate retaining components (retaining washer and snap ring) into a single integrated retaining element formed as one piece with the connector housing. This merging eliminates the need for separate retention components while maintaining the spring element's secure retention, thereby reducing assembly complexity and part count without sacrificing reliability
2Reliability
If multiple retaining components are used to hold the spring element, then the spring element is securely positioned, but the manufacturing and assembly cost increases
Solution Approach 1:
The retaining element is merged with the connector housing as an integral structure, eliminating the need to manufacture and assemble separate retaining components. This reduces the total number of parts, simplifies the supply chain, and lowers manufacturing and assembly costs while maintaining secure spring element positioning
3Device complexity
If a self-supporting compression element with integral retaining shim support is used, then the parts count and assembly complexity are reduced, but the element must withstand shock and vibration in harsh environments
Solution Approach 1:
The self-supporting compression element is segmented into distinct functional zones: a compressible spring element portion that provides compliance and a rigid retaining shim support portion that anchors to the housing. This segmentation allows each zone to be optimized for its specific function while working together as a unified structure that withstands harsh environmental conditions
Solution Approach 2:
The compression element appears to be constructed from materials with different mechanical properties - a more compliant material for the spring element portion and a more rigid material for the retaining shim support portion. This composite construction enables the element to simultaneously provide compliance where needed and structural integrity for retention in harsh environments
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
The design provides a robust and cost-effective solution for maintaining connector compliance in harsh environments, capable of withstanding shock and vibration while reducing assembly complexity and parts count.
Implementation Method 1
The spring element is compressible relative to the retaining shim support to allow the plug shell to move axially within the cavity of the outer coupling ring
Implementation Method 2
The spring element engages the rear facing support surface to support the plug shell within the cavity of the outer coupling ring
Data Source
Figure 1~2
Figure 3~4
AI summary
A circular plug connector (102) includes an outer coupling ring (130), a plug shell (120) and a self-supporting compression element (200) between the outer coupling ring and the plug shell. The plug shell houses plug contacts (126). The plug shell includes a mid-body (154) having a rear facing support surface (164). The self-supporting compression element surrounds the plug shell and includes a spring element (220) engaging the rear facing support surface. The self-supporting compression element includes a retaining shim support (222) integral with the spring element as a unitary, monolithic body (202) that is received in the retaining element (180) to fix the self-supporting compression element relative to the outer coupling ring. The spring element is compressible relative to the retaining shim support to allow the plug shell to move axially within the cavity (174) of the outer coupling ring.