Connector Coupling Mechanism for Blind Mating Feedback
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Solution Overview
Problem
In high reliability applications such as military and aerospace, existing connector systems face challenges in providing reliable mating feedback, especially in harsh environments with vibration, temperature swings, moisture, and chemical contaminants, where visual indicators may be obscured, and there is a risk of over-tightening or improper mating due to foreign object debris.
Innovation Solution
A connector with a coupling mechanism featuring an inner and outer coupling nut, where the outer coupling nut is automatically unlocked when fully mated, allowing free rotation and providing tactile and audible feedback, and a plunger mechanism that locks and unlocks to ensure proper engagement, preventing over-tightening and indicating full mating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual indicators are used to indicate proper mating, then mating status can be detected, but in densely populated areas or blind mating scenarios, the indicators become difficult or impossible to see
Solution Approach 1:
The patent replaces visual indicators with a mechanical feedback system. The coupling mechanism includes a plunger that moves axially and audibly clicks when the connector is fully mated. This mechanical-to-audible substitution allows mating status detection without visual line-of-sight, solving the problem of indicator visibility in blind mating scenarios.
Solution Approach 2:
The patent implements immediate mechanical feedback through the plunger mechanism. When the connector achieves full mating, the plunger is pushed axially and produces an audible click, providing real-time confirmation to the installer. This feedback loop eliminates the need for visual inspection and ensures proper mating status is communicated through sound and tactile sensation.
2Reliability
If connectors are tightened to ensure proper mating, then connection reliability is improved, but over-tightening can damage or destroy the connectors and contacts
Solution Approach 1:
The patent applies preliminary anti-action by designing the coupling mechanism to automatically prevent over-tightening. The plunger is positioned to engage with the coupling nut at the exact point of full mating, creating a mechanical stop that prevents any further tightening force from being applied. This pre-designed constraint protects the connector components from damage while ensuring reliable mating.
3Device complexity
If a single coupling nut is used, then the device complexity is reduced, but the ability to provide verified mating feedback and prevent over-tightening is compromised
Solution Approach 1:
The patent segments the coupling nut into two separate components: an inner coupling nut with threads that engage the connector shell, and an outer coupling nut that provides the feedback mechanism. The plunger is integrated with the outer coupling nut to detect when full mating is achieved. This segmentation allows the mechanism to provide verified mating feedback and prevent over-tightening while maintaining reasonable structural complexity.
Data Source
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AI summary
A connector (104) includes a shell (200) and a coupling mechanism (112) rotatable about the shell. The coupling mechanism includes inner and outer coupling nuts (220, 222). The inner coupling nut has threads (114) configured to be threadably coupled to a mating connector (102). The outer coupling nut is configured to be locked to the inner coupling nut to transfer rotation of the outer coupling nut to the inner coupling nut. The outer coupling nut is configured to be unlocked from the inner coupling nut to allow free rotation of the outer coupling nut relative to the inner coupling nut. The outer coupling nut is automatically unlocked when the connector is fully mated to the mating connector. The coupling mechanism may include a plunger movable between a locked position and an unlocked position with the plunger locking the outer coupling nut to the inner coupling nut in the locked position.