Electrical Connector Assembly with Intermediary Pin Alignment
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Solution Overview
Problem
Existing electrical connectors suffer from unstable connections due to users mistakenly believing the butt plug is fully inserted, leading to incomplete contact between the butt plug and the electrical connector, resulting in performance and efficiency issues.
Innovation Solution
The electrical connector assembly features a butt plug with engaging points that slide into corresponding fastening holes in the shield casing, ensuring proper alignment and contact, with the fastening holes located behind punched holes to prevent misalignment and damage from friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the engaging points pass through the punched holes to engage with the fastening holes, then the electrical connection is established, but the user easily mistakes the insertion depth and stops pushing early, resulting in unstable electrical connection
Solution Approach 1:
The pin acts as an intermediary mechanical element between the engaging point and the fastening hole. The pin protrudes from the side wall and must be fully inserted into the engaging point, providing a clear mechanical indication that the connector is fully inserted. This intermediary structure eliminates the ambiguity of judging insertion depth by visual inspection alone, ensuring reliable electrical connection.
Solution Approach 2:
The patent uses visual differentiation through color or positional indication of the pin relative to the side wall. When the pin is fully inserted into the engaging point, it provides a visible signal (such as color change or positional alignment) that indicates complete insertion has been achieved, solving the user's difficulty in judging insertion depth.
2Ease of operation
If the punched holes are formed on the bottom wall, then the engaging points can pass through them, but the engaging points may fall into the punched holes instead of reaching the fastening holes, causing contact failure
Solution Approach 1:
The pin serves as a guiding intermediary that prevents the engaging point from falling into the punched hole. The engaging point is designed to engage with the pin first, and the pin's structure ensures that the engaging point is guided along a controlled path to the fastening hole, preventing it from deviating into the punched hole.
Solution Approach 2:
The pin is pre-positioned on the side wall before the engaging point is inserted. The engaging point is designed to first engage with the protruding pin, which then guides it to the correct position at the fastening hole. This preliminary positioning action prevents the engaging point from mistakenly entering the punched hole.
Data Source
AI summary
An electrical connector assembly of the invention comprises a butt plug with a contact portion and an electrical connector capable of matching the butt plug. One side of the contact portion has at least one engaging point. The electrical connector comprises an insulating body and a shield casing with at least one bottom wall. A side wall extends upward from at least one side of the bottom wall and the side wall covers at least one part of the insulating body. An opening, which is located at the front of the bottom wall and the side wall, is used for receiving the contact portion. The bottom wall has at least one fastening hole matching the engaging point. Enable the engaging point to slide into the corresponding fastening hole in parallel. When the butt plug is inserted into the shield casing once, the invention can ensure good electrical connection.