Quick-Connect Electrical Connector Locking for Vibration Resistance
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Solution Overview
Problem
Existing power delivery systems in aircraft environments face challenges such as arcing, vibration resistance, and complex installation processes due to exposed 'hot' contact surfaces and lack of reconfigurability in terminal block arrangements, necessitating a robust and efficient electrical connection solution.
Innovation Solution
A quick connect electrical connector system featuring modular sockets and conductive elements with a dovetail joint and spring-biased locking mechanism, allowing for easy assembly and disassembly, and utilizing insulating materials like polyamide-imide for durability and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminal blocks with exposed hot contact surfaces are used, then electrical connections can be established, but arcing and safety issues occur
Solution Approach 1:
The connector element is inserted into a receptacle that provides a recessed cavity, creating a nested structure where the contact surfaces are enclosed rather than exposed. This nesting eliminates arcing by containing the electrical contact within the recessed space, while still allowing reliable electrical connection between the connector and receptacle.
Solution Approach 2:
A resilient locking member acts as an intermediary between the connector element and receptacle. This locking member engages with both components to secure the connection while maintaining enclosed contact surfaces, thereby preventing arcing while ensuring reliable electrical connection.
2Reliability
If connectors are bolted down to terminal blocks, then secure connections are achieved, but installation time increases
Solution Approach 1:
The traditional bolted mechanical fastening system is replaced with a spring-biased locking mechanism. The resilient locking member uses elastic deformation and mechanical engagement features (such as cam surfaces or detent mechanisms) to secure the connector element quickly without requiring bolts, thereby maintaining connection security while dramatically reducing installation time.
Solution Approach 2:
The resilient locking member is designed to automatically engage and lock the connector element into the receptacle through its own elastic deformation and mechanical features, without requiring external fastening operations. The locking mechanism self-activates during insertion, providing secure connection instantly without manual intervention beyond simple insertion.
3Ease of manufacture
If screw-together connector elements are used, then connections can be made, but reconfiguration for multiple contact assembly is difficult
Solution Approach 1:
The electrical connection system is divided into separate, modular components: individual connector elements and corresponding receptacle positions. Each connector element can be independently inserted, removed, or replaced in its receptacle, allowing flexible reconfiguration of the multiple contact assembly without affecting other connections. This segmentation enables easy adaptation to different configuration requirements.
Solution Approach 2:
The locking mechanism incorporates dynamic elements that allow the connector element to transition between locked and unlocked states. The resilient locking member can be actuated to release the connector element from the receptacle, enabling easy reconfiguration. The dynamic nature of the locking mechanism allows for quick insertion and removal, providing versatility in assembling different contact configurations.
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 system provides a secure, efficient, and adaptable power signal delivery solution that is resistant to vibration and environmental stress, with rapid connection and disconnection capabilities, enhancing safety and reducing installation time.
Implementation Method 1
a spring member disposed about the cylindrical body and biasing the locking ring forwardly into a position such that the forward portion is disposed about the groove
Implementation Method 2
A series of spring fingers are configured to snap into and out of engagement with the peripheral groove
Data Source
Figure 1
Figure 1A
Figure 2
AI summary
An electrical connector system (10) includes a connector (20) with a plug (50). A shroud (54) extends over a portion of the plug (50) and is coupled with the plug. A conductive socket (14) is configured for receiving the plug (50) of the connector. The socket (14) includes a groove (72) formed on an outer surface thereof. The shroud includes spring fingers (58) having a lock portion (70) thereon configured for engaging the groove (72) for securing the connector (20) in the socket. A collar (80) is slidably mounted on the conductive socket (14) and is configured for sliding between a locked position proximate to the socket groove (72) and an unlocked position. The collar (80) is further configured for engaging the spring fingers (58) of the connector shroud (54) in the locked position to hold the finger lock portions (70) engaged with the groove (72) to lock the connector in the socket.