Electrical Connector Locking Structure for Secure Quick Coupling
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Solution Overview
Problem
Existing electrical connectors for power tools and appliances often fail to provide a safe and secure connection, leading to potential injury and downtime due to accidental uncoupling, especially in hazardous work environments, and are cumbersome or prone to snagging, increasing the risk of damage and unsafe work practices.
Innovation Solution
An electrical connector system featuring a plug and socket design with locking balls and rotatable retainers that secure electrical conduits, providing an IP rating through snap-fit connectors and flange elements to prevent rotational and longitudinal movement, ensuring a snug and reliable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical connectors are used, then the connection can be established quickly, but the connection is not secure and may uncouple accidentally during operation
Solution Approach 1:
The connector features a self-locking mechanism where the locking ball automatically engages with the locking groove when the plug is inserted into the socket. The spring-loaded design causes the locking ball to protrude and snap into the groove without requiring additional manual locking actions, providing secure connection automatically
Solution Approach 2:
The invention replaces traditional threaded or multi-step mechanical locking systems with a simple ball-and-groove mechanical latch system. This substitution maintains connection security while dramatically simplifying the connection process to a single insertion motion
2Reliability
If external locking devices are used to secure the connection, then the connection becomes more secure, but the device becomes bulky and prone to snagging
Solution Approach 1:
The locking ball is nested within the housing of the plug or socket, concealed inside the connector body. The external profile remains smooth and compact without protruding locking mechanisms, eliminating snagging hazards while maintaining secure internal locking
Solution Approach 2:
The locking mechanism is extracted from the external surface and placed entirely within the internal structure of the connector. The locking ball operates inside the housing, with only the engagement interface visible, removing bulky external components
3Reliability
If threaded connections are used, then the connection can be secured tightly, but additional alignment and rotation steps are required
Solution Approach 1:
The spring-loaded locking ball automatically performs the tightening function upon insertion. The spring force drives the ball into the locking groove, creating immediate tight engagement without requiring manual rotation or tightening steps
4Reliability
If multiple locking mechanisms are used, then the connection becomes more secure, but the device becomes more complex and difficult to assemble
Solution Approach 1:
The locking ball serves multiple functions simultaneously: it provides the locking engagement, acts as a positioning element, and enables the self-locking mechanism. This single component performs what would traditionally require multiple separate locking elements
Data Source
AI summary
An electrical connector comprises a plug connector and a socket connector connectable to respective electrical conduits, wherein the plug connector and at least partly prevent or minimize rotational and/or longitudinal movement of the electrical conduits relative to the connectors. The socket connector may comprise a rotatable retainer comprising one or more flange members and the plug connector may comprise one or more complementary flange members, so that rotation of the retainer facilitates engagement between the respective flange members of the socket connector and the plug connector. Power sources are also provided which comprise the hereinbefore described rotatable retainer and flange elements.