Electrical Connector Coupling System Vibration Resistance
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Solution Overview
Problem
Conventional electrical connector assemblies often loosen due to vibration, compromising the integrity of the electrical connection between components.
Innovation Solution
A coupling system with both inner and outer engagements, utilizing conical tapered surfaces with a specific angle of taper (3.5° to 6.5°) for a friction fit and threaded engagements to securely mate the connector members, preventing loosening during movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrical connector assemblies use simple engagement mechanisms, then the device complexity is low, but the reliability deteriorates due to loosening under vibration
Solution Approach 1:
The coupling system is divided into two distinct engagement mechanisms: an inner friction fit engagement between tapered surfaces and an outer threaded engagement between the coupling member and receptacle body. This segmentation allows each mechanism to contribute differently to the overall connection stability, with the inner engagement providing initial alignment and the outer engagement providing vibration resistance.
Solution Approach 2:
The patent combines two different engagement mechanisms (friction fit and threaded engagement) into a single integrated coupling system. The inner tapered surfaces provide friction-based alignment while the outer threaded coupling member provides mechanical locking, creating a hybrid system that leverages the advantages of both engagement types to prevent loosening under vibration.
2Reliability
If the angle of taper is too shallow, then the friction fit is too loose compromising connection integrity, but if the angle is too steep, then the assembly force required increases excessively
Solution Approach 1:
The patent specifies a precise range for the taper angle (3.5° to 6.5°) to optimize the balance between friction fit integrity and assembly force requirements. This parameter optimization ensures that the tapered surfaces generate sufficient friction to maintain connection integrity while requiring reasonable assembly forces that do not exceed practical limits.
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 system provides a secure mechanical and electrical connection that remains stable during vibration, ensuring reliable contact between the plug and receptacle members.
Implementation Method 1
The first and second tapered surfaces have substantially the same angle of taper and taper in opposite directions to engage one another in a friction fit wherein the angle of taper is between about 3.5° to 6.5°. The friction fit forms an inner engagement between the first and second connector members.
Data Source
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AI summary
An electrical connector assembly that comprises a first connector member including a first connector body supporting a first contact. The first connector body is formed of a substantially rigid material and has a first interface end. The first interface end has a substantially conical shape that defines a first tapered surface. A second connector member includes a second connector body supporting a second contact configured to mate with the first contact. The second connector body is formed of a substantially rigid material and has a second interface end that mates with the first interface end. The second interface end of the second connector member has a second tapered surface. The first and second tapered surfaces have substantially the same angle of taper and taper in opposite directions to engage one another in a friction fit wherein the angle of taper is between about 3.5° to 6.5°. A coupling member is mounted near one of the first and second interface ends and has an internal engagement member that is configured to engage a corresponding external engagement member of the other of the first and second connector bodies.