One-Piece Opening Element for Connector Plug Flap Actuation
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Solution Overview
Problem
Existing connector designs for optical and electrical plug connections often require complex mechanisms to protect sensitive contacts, which can lead to operational unreliability and manufacturing complexities, especially when using flaps for protection.
Innovation Solution
A simplified one-piece opening element with a first contact surface for the elastic prestressing element and a second contact surface to open the flap, designed as a pin-like or ring-shaped element, is used, along with a counter-stop to prevent displacement, facilitating easy manufacturing and reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex mechanism is used to protect sensitive contacts with flaps, then contact protection is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The opening element combines multiple functions into a single component: it acts as both the actuator to open the flap and the guide for the optical/electrical contact. This merging eliminates the need for separate complex mechanisms while maintaining reliable contact protection and opening functionality.
Solution Approach 2:
The opening element serves multiple purposes simultaneously: it opens the protective flap, guides the contact through the housing, and can be prestressed to ensure proper sequencing of operations. This multi-functionality reduces overall device complexity while maintaining reliability.
2Reliability
If a complex mechanism is used to protect sensitive contacts, then contact protection is improved, but ease of manufacture deteriorates due to increased undercuts
Solution Approach 1:
By combining the opening element and contact guide into a single component, the number of mold parts and assembly steps is reduced. The simplified geometry with fewer undercuts makes injection molding easier and more cost-effective while maintaining contact protection functionality.
3Ease of manufacture
If the opening element is designed as a one-piece body, then ease of manufacture is improved, but operational reliability may deteriorate without proper guidance
Solution Approach 1:
The housing provides an intermediary guiding structure with a guide surface that ensures the one-piece opening element moves along the correct path. This intermediary guidance mechanism maintains operational reliability while allowing the opening element to remain a simple one-piece component for easy manufacturing.
4Ease of operation
If the opening element is displaced in directions parallel to mating direction, then flap opening functionality is achieved, but the element may be pushed out of the connector housing
Solution Approach 1:
The counter-stop is positioned in advance to prevent the opening element from being pushed out of the housing. This preliminary restraining structure counteracts the force that would otherwise eject the element, allowing safe displacement for flap opening while maintaining position stability.
Solution Approach 2:
The counter-stop creates an asymmetric constraint that allows displacement in the desired direction (parallel to mating direction for opening) while preventing displacement in the opposite direction (out of the housing). This asymmetric design enables controlled movement with built-in safety.
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 ensures reliable and efficient opening of the flap before contact insertion, preventing damage and simplifying the manufacturing process by reducing undercuts, while maintaining operational reliability and ease of assembly.
Implementation Method 1
an elastic opening prestressing element acting in the direction of mating and being prestressed by the opening prestressing element
Data Source
Figure 1
Figure 2~5
AI summary
Connector part (1) for producing an optical and/or electrical connection (2) with a mating connector part (3) by connecting the connector part (1) with the mating connector part (3) in at least one connection direction (4), wherein the connector part (1) has a connector housing (5) and at least one optical and/or electrical contact (6) and an elastic opening preload element (7) acting in a direction parallel to the connection direction (4) and an opening element (8) for opening a flap (9) on the mating connector part (3), wherein the opening element (8) is slidably mounted in or on the connector housing (5) in directions parallel to the connection direction (4) relative to the connector housing (5) and is preloaded in one of these directions parallel to the connection direction (4) by the opening preload element (7),wherein the opening element (8) is designed as a one-piece body and has a first contact surface (10) for the opening preload element (7) and a second contact surface (11) for opening the flap (9) of the mating plug part (3).