Electrical Connector Guide Groove Geometry for Misaligned Insertion

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Solution Overview

Problem

Existing electrical connectors suffer damage when the socket connector is inserted in a significantly inclined state, causing deformation of the plug connector's insertion slot.

Innovation Solution

The electrical connector design includes a male connector with surface portions featuring a first recess and a female connector with a first protrusion, where the male connector's inclined surface and the female connector's protrusion satisfy specific dimension and angle relations to guide proper alignment and insertion, preventing damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the socket connector is inserted in a significantly inclined state, then the insertion operation can be performed, but the insertion slot deforms and damage occurs to the plug connector

Engineering Contradiction:

Improveinsertion operationVSAvoiddamage to plug connector

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent applies preliminary action by providing an inclined surface on the insertion slot before the actual insertion occurs. This inclined surface guides the socket connector to transition from an inclined state to an aligned state during the insertion process, preventing damage before it happens. The guide ribs and guide grooves are pre-positioned to automatically align the connectors as they engage.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses guide ribs and guide grooves as intermediary elements between the plug connector and socket connector. These intermediaries facilitate the transition from inclined to aligned positioning, mediating the insertion process to prevent direct damage to the insertion slot while still allowing the connection to be made.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If the inclined surface angle is increased to accommodate larger inclination angles, then the range of acceptable insertion angles is improved, but the insertion slot may still deform under excessive force

Engineering Contradiction:

Improverange of insertion anglesVSAvoidresistance to insertion slot deformation

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The patent applies parameter changes by optimizing the inclination angle of the inclined surface and the dimensions of the guide ribs and grooves. These parameters are specifically designed to convert insertion forces into aligning forces, allowing the system to accommodate a range of insertion angles while maintaining strength and preventing deformation through proper geometric parameter selection.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20250279608A1Electrical connector

Publication Date: 2025.09.04 I PEX INC

AI summary

Side wall portions of a male connector that define a housing space includes first recesses having a shape of a groove extending along an insertion direction. A female connector includes a first protrusion that has a shape of a convexity extending along the insertion direction, and fitting in the first recess. The first recess of the male connector includes an inclined surface, the inclined surface being inclined relative to the insertion direction. The male connector and the female connector satisfy relation equationsA>α×B(1)(where⁢ 1≤α≤1.0641)25⁢°≤Y≤45⁢°(2)provided that a dimension of the groove of the first recess is A, a dimension of a width of the first protrusion is B, and an inclination angle of the inclined surface relative to the insertion direction is Y.