Plug Connector Locking Assembly for Compact Battery Module Connections
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Solution Overview
Problem
Conventional plug connector systems fail to meet the requirements of complex applications, such as battery systems, in terms of installation size, operability, and flexibility, particularly in environments with mechanical stress, temperature variations, and high humidity, while also ensuring reliable and secure connections.
Innovation Solution
A plug connector system with a locking element integrated into the socket housing that can be coupled with the pin housing, featuring a transversely movable assurance for locking and secondary contact assurance, allowing for efficient assembly and disassembly without increasing installation size, and incorporating a resilient prefixing element for precise positioning and elasticity to adapt to various conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional securing components and locking mechanisms are added to ensure reliable connection, then connection reliability is improved, but installation size and device complexity increase
Solution Approach 1:
The patent integrates the locking mechanism directly into the housing structure of the plug connector system. The housing incorporates interlocking elements and locking features as integral parts of its design, eliminating the need for separate locking components. This merging of functions reduces the number of parts while maintaining secure connection reliability.
Solution Approach 2:
The housing structure serves multiple functions simultaneously: it provides mechanical support, electrical insulation, and integrated locking/securing mechanisms. The design combines these functions into a single multi-functional component, reducing overall device complexity while ensuring reliable connections.
2Reliability
If additional securing components and locking mechanisms are added to ensure reliable connection, then connection reliability is improved, but installation size increases
Solution Approach 1:
The locking and securing functions are merged into the housing structure itself, eliminating the need for additional separate components. This integration allows the connector to maintain reliable connections without increasing installation size, as the housing serves as both the structural support and the locking mechanism.
3Reliability
If robust locking and securing measures are implemented, then connection reliability is improved, but assembly and disassembly effort increase
Solution Approach 1:
The locking mechanism is designed to engage automatically upon insertion of the plug connector. The housing structures self-lock through integrated interlocking elements that engage when the connectors are mated, eliminating the need for manual locking operations. For disassembly, the design includes simple release mechanisms that allow easy decoupling without complex procedures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a compact, reliable, and adaptable plug connector system that ensures secure connections while reducing installation size and enhancing operability, flexibility, and accessibility, even under challenging environmental conditions.
Implementation Method 1
a resilient prefixing element for fixation with a clearance determined by the elasticity of the prefixing element
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
The present invention provides a plug connector system. According to one aspect, a locking element is provided on the socket housing of the system such that a superior degree of flexibility may be achieved upon mounting and connecting the plug connector system, in particular, in critical applications, such as usage in combination with battery modules. In a further aspect, a socket housing and/or a pin housing of the plug connector system are provided with a resilient prefixing element in order to achieve a preliminary fixation corresponding to a degree of elasticity, thereby allowing tolerances to be taken into consideration. In a further aspect, the plug connector system comprises an assurance having a double function, thereby accomplishing the secondary assurance of contacts and the locking of the housing components on the basis of one single component.