Connector Cover Ribs Prevent Misalignment

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Solution Overview

Problem

Existing polarized or keyed connectors, such as MOLEX connectors, can still be incorrectly oriented during installation or repair, leading to potential damage from incorrect currents or voltages applied to electrical components.

Innovation Solution

A connector cover designed to snap onto, snap together, or slip onto the keyed connector housing, featuring ribs and key structures that prevent misalignment by mechanically interfering with incorrect orientations, ensuring correct electrical contact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If polarized or keyed connectors are used to ensure correct orientation, then connection reliability is improved, but the risk of misconnection during installation or repair still exists

Engineering Contradiction:

Improveconnection reliabilityVSAvoidmisconnection risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A cover component is introduced as an intermediary element between two connectors. The cover includes a body portion that fits over the first connector and a protrusion that extends toward the second connector, physically blocking misaligned connections while allowing correct orientation mating.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The cover is pre-installed on the first connector before the second connector is brought into position. The protrusion on the cover creates preliminary mechanical interference that prevents the second connector from being inserted in incorrect orientations, stopping the harmful action before it can occur.

Inventive Principle:

Principle #9Preliminary anti-action

2Object-affected harmful factors

If connector covers with mechanical interference features are added, then misconnection prevention is improved, but device complexity increases

Engineering Contradiction:

Improvemisconnection preventionVSAvoidconnector system complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The connector system is divided into separate components: the original connectors and an additional cover component. The cover is further segmented into a body portion and a protrusion feature, allowing independent manufacturing and assembly of simple parts that together provide misconnection prevention.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cover appears to be designed as a simple, inexpensive protective component that can be easily manufactured and installed. Its primary function is misconnection prevention during critical installation or repair operations, after which it remains as a simple protective cover.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUS9917404B1Connector covers and systems to prevent misconnections

Publication Date: 2018.03.13 BALBOA WATER GROUP LLC

AI summary

Embodiments of a connector cover are described, which are easily attached to a keyed electrical connector housing, and which prevent misconnection with a mating connector. One embodiment features a snap-on design, in which the cover simply snaps onto the keyed connector housing. A second embodiment is in the form of a two-piece cover, which snap together about the keyed connector housing. A third exemplary embodiment features a slip-on design, in which the cover slips onto the keyed connector housing. In another aspect, an electrical connector system is described, which includes the connector cover and first and second keyed electrical connectors.