Clamshell Ceramic Connector Hinged Insertion
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Solution Overview
Problem
Conventional high temperature electrical connectors for gas sensors require high insertion forces, which can damage the contact pads and are not suitable for many applications due to their non-resilient nature, necessitating an improved design that balances insertion ease with sufficient contact force and facilitates assembly.
Innovation Solution
A clamshell connector with a ceramic body and retainer that hinges open for low insertion force and closes to apply a higher contact force, featuring conductive terminals within the ceramic body portions and a retainer with arched hinges and inwardly extending arms for secure engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional high temperature electrical connector with fixed ceramic body and terminals is used, then the connector provides stable electrical contact, but it requires high insertion force that can damage contact pads
Solution Approach 1:
The connector body is designed with resilient arms that can flex during insertion and then maintain constant contact force. The arms are engineered to deflect under insertion load and then spring back to apply sustained contact pressure, transforming a static rigid structure into a dynamic resilient one that adapts to insertion forces while maintaining reliable electrical contact.
Solution Approach 2:
The resilient arms are pre-loaded with spring force before insertion occurs. This pre-loading creates a cushioning effect that absorbs the insertion shock and prevents direct transmission of high insertion forces to the contact pads, while still ensuring adequate contact force is maintained after insertion.
2Ease of operation
If a clamshell configuration with opposing ceramic body halves is used, then the connector can receive the sensor with low insertion force, but the positions of the body and terminals are fixed making it non-resilient
Solution Approach 1:
The clamshell halves are connected through resilient arms that enable relative movement between the halves during insertion, then maintain constant contact force through spring deflection. This creates a dynamic system where the resilient arms absorb insertion shocks and sustain reliable electrical contact throughout operation.
Solution Approach 2:
The resilient arms are designed with specific spring rates and deflection characteristics that allow the connector to transition from a rigid fixed-position structure to one that dynamically adjusts contact parameters. The spring deflection varies during insertion to accommodate low insertion force requirements while maintaining adequate contact force in the installed state.
3Reliability
If a solid metal retaining ring is used to close the clamshell connector halves, then the connector body is retained securely, but the assembly process becomes complex
Solution Approach 1:
The retaining ring is segmented into resilient arms that are integrated with the clamshell halves rather than being a separate solid component. This segmentation allows the retaining structure to flex and spring back during assembly, enabling simple snap-fit installation without requiring complex fastening operations or additional fasteners.
Solution Approach 2:
The resilient arms are designed to automatically engage and retain the connector body through their own spring force during assembly, eliminating the need for separate fastening operations. The arms deflect during insertion and then self-lock into position, providing secure retention through their inherent elastic properties rather than requiring external fastening mechanisms.
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 allows for easy sensor insertion with reduced risk of damage, maintaining reliable contact forces and facilitating compact, flexible sensor mounting with reduced material usage and improved responsiveness in emission control systems.
Implementation Method 1
a retainer with arched hinges and inwardly extending arms for secure engagement
Implementation Method 2
These electrical connectors are exposed to the extreme operating temperatures of internal combustion engine exhaust systems, which may include temperatures at the connector of greater than 200° C. and up to about 350° C. Thus, these connectors generally have connector bodies made from high temperature materials, such as ceramics.
Data Source
AI summary
A high temperature electrical connector suitable for use in a high temperature gas sensor. The electrical connector incorporates a ceramic connector body having a pair of opposing ceramic body portions which each house a plurality of conductive terminals. The body portions are in pivoting engagement and fixed in a connector body retainer which also enables their pivoting, hinged movement. The pivoting engagement permits the ceramic body portions and terminals to hinge open to receive a gas sensor with a low insertion force and a hinge closed to provide the desired contact force. The ceramic body portions may also include a taper section in a pivot portion with a taper angle that may be varied to control the pivoting, hinged movement of the electrical connector.