Electrical Connector Movable Guard Contact Protection

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Solution Overview

Problem

Existing electrical connectors are vulnerable to contamination and mechanical damage due to exposed contacts, which can lead to improper engagement and damage during shipping or handling, necessitating replacement.

Innovation Solution

An electrical connector assembly featuring a movable dielectric guard with clearance and frictional thru-holes that slides along the central axis to protect the contacts, reducing exposure and preventing damage by aligning and holding contacts in designated positions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the electrical contacts are exposed at the front end of the connector housing, then the connector can be easily mated with the mating connector, but the electrical contacts are vulnerable to contamination and mechanical damage

Engineering Contradiction:

Improvemating operationVSAvoidcontamination and mechanical damage

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The movable guard is positioned in advance at the forward position to protect the electrical contacts before mating occurs. The guard pre-establishes a protective barrier that prevents contaminants and objects from reaching the contacts during shipping and handling, while still allowing the mating connector to be inserted when needed.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The guard is designed to be movable along the central axis rather than fixed, allowing it to dynamically adjust its position. It can slide forward to protect contacts during shipping, and slide backward when the mating connector is inserted to permit engagement. This dynamic behavior resolves the contradiction between protection and ease of mating.

Inventive Principle:

Principle #15Dynamics

2Object-affected harmful factors

If a protective cover is added to shield the electrical contacts, then the contacts are protected from contaminants and damage, but the connector structure becomes more complex

Engineering Contradiction:

Improveprotection from contaminantsVSAvoidconnector structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The movable guard serves multiple functions: it protects electrical contacts from contaminants and mechanical damage, guides the mating connector during insertion, and can be actuated by the mating connector itself to move to the retracted position. By combining these functions into a single component, the design achieves protection without proportionally increasing complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The mating connector itself acts as the actuating mechanism for the movable guard. As the mating connector is inserted into the receiving cavity, it automatically engages and pushes the guard backward to its retracted position. This self-actuating mechanism eliminates the need for separate actuators or complex control systems, reducing overall device complexity while maintaining effective protection.

Inventive Principle:

Principle #25Self-service

3Stability of the object's composition

If the movable guard is held at the forward position by friction, then the guard remains stable during shipping, but the guard may not move easily when mating is required

Engineering Contradiction:

Improveguard position stabilityVSAvoidguard movement

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The dielectric sheet is designed with different types of thru-holes at different locations: frictional thru-holes that engage specific electrical contacts to provide strong holding force at the forward position, and clearance thru-holes that allow free movement. This local differentiation of engagement characteristics allows the guard to be firmly held when needed while still permitting easy movement when actuated by the mating connector.

Inventive Principle:

Principle #3Local quality

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 effectively shields contacts from contaminants and objects, reducing the likelihood of stubbing and contact damage, ensuring reliable operation and extending the lifespan of the connector.

Implementation Method 1

the inner edges of the frictional thru-holes engage corresponding electrical contacts of the contact array to hold the movable guard at a forward position within the receiving cavity

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentEP3161910B1Electrical connector assembly comprising an array of elongated electrical contacts

Publication Date: 2018.12.12 TE CONNECTIVITY CORP

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AI summary

Electrical connector assembly (100) including a connector housing (108) having a front end and a receiving cavity (118) that opens to the front end. The receiving cavity is configured to receive a mating connector therein that is inserted into the receiving cavity along a central axis. The electrical connector assembly also includes a contact array (130) of electrical contacts (132, 133) that is disposed within the receiving cavity. The electrical contacts have elongated bodies that extend generally parallel to the central axis through the receiving cavity. The electrical connector assembly also includes a movable guard that is configured to be slidably held by the contact array within the receiving cavity. The movable guard includes a dielectric sheet that extends transverse to the central axis and has an array of thru-holes. Inner edges of the thru-holes engage corresponding electrical contacts to slidably hold the movable guard at a forward position within the receiving cavity.