Electrical Connector Fool-Proof Protrusion Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connectors lack a fool-proof mechanism to prevent damage from incorrect mating angles, leading to failed data and power transmission and terminal damage.
Innovation Solution
An electrical connector design featuring a fool-proof protrusion that extends beyond the outer surface perpendicular to the insertion direction, located on either side of the slot, to prevent incorrect angular insertion by the mating connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrical connector is designed without a fool-proof mechanism, then the structure is simpler and easier to manufacture, but the terminals are vulnerable to damage from incorrect insertion angles
Solution Approach 1:
The fool-proof protrusion is designed in advance on the connector housing to prevent incorrect insertion before it can occur. This preliminary protective structure blocks wrong-angle insertion attempts before they reach the vulnerable terminals, resolving the contradiction by providing protection without requiring complex active sensing or locking mechanisms.
Solution Approach 2:
The fool-proof protrusion creates an asymmetric physical barrier that only allows insertion at the correct angle. This asymmetric design passively prevents wrong-angle insertion through geometric constraint rather than complex mechanical interlocking, maintaining structural simplicity while improving reliability.
2Object-affected harmful factors
If a fool-proof protrusion is added to prevent wrong-angle insertion, then terminal damage is prevented, but the manufacturing complexity increases
Solution Approach 1:
The fool-proof protrusion is integrated into the existing connector housing structure rather than being a separate component. This merging approach allows the protective function to be added during the same molding or fabrication process as the housing itself, minimizing additional manufacturing steps and complexity.
3Reliability
If the fool-proof protrusion is positioned to effectively block wrong-angle insertion, then transmission function is protected, but the device structure becomes more complex
Solution Approach 1:
The fool-proof protrusion provides localized protection at the specific insertion interface where wrong-angle insertion occurs. This localized approach protects the critical transmission function without requiring complex structural modifications throughout the entire connector assembly, maintaining overall design simplicity.
Data Source
AI summary
The present disclosure discloses an electrical connector including an insulating body, a number of conductive terminals and a shielding shell. The insulating body includes a mating surface and a slot. Each conductive terminal includes a contact portion extending into the slot. A receiving groove for receiving a part of a mating connector is formed between the shielding shell and the insulating body. The receiving groove is located outside the slot. The electrical connector further includes a first outer surface and a fool-proof protrusion protruding beyond the first outer surface in a direction perpendicular to an insertion direction of the mating connector. The first outer surface and the receiving groove are located on two opposite sides of the slot, respectively. The fool-proof protrusion is adapted to prevent the mating connector from being inserted into the electrical connector at a wrong angle.