Electrical Connector Locking System for Large Contacts
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Solution Overview
Problem
Existing electrical connectors with locking systems prove inefficient for larger contacts, as they fail to securely engage and maintain the contacts during assembly and disassembly.
Innovation Solution
The electrical connector employs a combination of longitudinal protrusions and grooves, along with flexible lances and pivotable levers, to ensure secure engagement and locking of both small and large electrical contacts within the connector's housings, utilizing a system of cooperating ribs and grooves to guide and lock the contacts into place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flexible lance locking system is used for electrical contacts, then small contacts can be securely locked, but larger contacts cannot be effectively locked
Solution Approach 1:
The locking system is segmented into two independent components: a flexible lance for small contacts and a pivotable lever for large contacts. Each component is optimized for its specific contact size range, allowing the connector to reliably lock both small and large contacts without compromise.
Solution Approach 2:
The pivotable lever introduces a dynamic locking mechanism that can adapt to larger contacts. The lever pivots between locked and unlocked positions, providing the necessary mechanical advantage and adaptability for securing larger contacts that the rigid flexible lance cannot handle.
2Device complexity
If a single locking mechanism is used for all contact sizes, then device complexity is reduced, but locking effectiveness for larger contacts deteriorates
Solution Approach 1:
Rather than attempting to design a single universal locking mechanism, the system is divided into two specialized subsystems. The flexible lance handles small contacts while the pivotable lever handles large contacts, ensuring each component can be optimized for its specific function without compromising overall reliability.
Solution Approach 2:
Different locking mechanisms are applied to different contact sizes based on their specific requirements. Small contacts receive the flexible lance locking while large contacts receive the pivotable lever locking, ensuring each contact type receives the appropriate level and type of securing force.
3Manufacturing precision
If longitudinal protrusions and grooves are added to guide and lock contacts, then contact positioning precision is improved, but device complexity increases
Solution Approach 1:
The guiding and locking functions are merged into the same longitudinal protrusions and grooves. These features simultaneously serve to guide contacts into proper alignment during insertion and to lock them in position, eliminating the need for separate guiding and locking mechanisms.
Solution Approach 2:
The longitudinal protrusions and grooves perform multiple functions: they guide contacts during insertion, maintain alignment during connection, and provide locking engagement. This multi-functionality reduces the need for additional specialized components despite the increased structural complexity.
Data Source
AI summary
An electrical connector comprising: -one or more housings (H), - a carrier (C) adapted to receive the housing(s). The housing comprises a flexible lance (10) adapted to flex to maintain an electrical contact in the receptacle. The carrier comprises a protrusion (2; 4) : -when the lance (10) is in its unlock condition, the lance (10) cooperates with the protrusion (2; 4), - when the lance (10) is in its lock condition, the lance (10) does not cooperate with the protrusion (2, 4).