Electrical Connector Full-Mate Indicator via Rotatable Check Member

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Solution Overview

Problem

It is challenging to determine when electrical connector pairs are fully mated, especially when high torque is required for coupling, as existing technologies lack a clear indication of the mating status.

Innovation Solution

An electrical connector with a coupling nut and an indicator system comprising a clamp member and a check member, where the indicator is non-rotatable when fully mated and rotatable when not fully mated, allowing users to confirm the mating status through torque application.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If high torque is applied for coupling the connectors, then the connection strength is improved, but it becomes difficult to determine when the connectors are fully mated

Engineering Contradiction:

Improveconnection strengthVSAvoidmating status detection

Core Design Contradiction:

StrengthVSDifficulty of detecting and measuring

Solution Approach 1:

The indicator includes a check member with a visible portion that can be seen through the coupling nut. When the connector is fully mated, the indicator assumes a first orientation with the visible portion of the check member visible through the coupling nut, providing a visual color/position change to indicate full mating status

Inventive Principle:

Principle #32Color changes

Solution Approach 2:

The indicator system acts as an intermediary between the high-torque coupling mechanism and the user. It translates the mechanical state of the connector (mated vs. unmated) into a visible signal, allowing users to determine mating status without needing to sense torque directly

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If an indicator system is added to show mating status, then the ease of operation is improved, but the device complexity increases

Engineering Contradiction:

Improvemating status indicationVSAvoidconnector structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The indicator is integrated within the coupling nut structure. The clamp member is received by the coupling nut, and the check member is positioned within the coupling nut, merging the indicator function with the existing coupling mechanism rather than adding completely separate components

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The coupling nut serves multiple functions: it provides the threaded coupling mechanism for joining connectors and simultaneously houses the indicator system to display mating status. The visible portion of the check member can be seen through the coupling nut, allowing the coupling nut to serve both mechanical and informational roles

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11637398B2Electrical connector with full-mate indicator

Publication Date: 2023.04.25 AMPHENOL CORP

AI summary

An electrical connector includes a connector shell, a coupling nut, and an indicator surrounding the connector shell. The indicator includes a clamp member and a check member. The clamp member includes a ring and a coupling structure extending from the ring to the check member and coupling the ring to the check member. The indicator may assist a user in determining if the electrical connector is in a fully-mated state.