Electrical Connector Secondary Lock With Radial Actuation
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Solution Overview
Problem
Existing electrical connector systems require complex secondary locking mechanisms that are difficult to implement and operate, often involving multiple components, which can complicate the assembly and ensure secure connections under tension.
Innovation Solution
An electrical connector design featuring a secondary locking element that can be moved radially inward from an intermediate to a fixed end position, securely locking the plug contact against removal, using a separate component that interacts with the contact carrier and plug contact to provide a simple and effective locking mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a secondary locking mechanism is implemented to secure the plug contact in the contact carrier, then the connection reliability is improved, but the device complexity increases due to multiple components
Solution Approach 1:
The secondary locking element integrates multiple functions into a single component: it provides secondary locking, guides the plug contact during insertion, and interacts with the contact carrier to secure the connection. This merging of functions reduces the number of separate components while maintaining reliability.
Solution Approach 2:
The secondary locking element serves multiple purposes within the connector system: it acts as a locking mechanism, a positioning guide, and a structural support element. This multi-functionality allows a single component to address multiple requirements, reducing overall device complexity.
2Strength
If a secondary locking element is added to secure the plug contact against removal, then the tensile strength is improved, but the ease of manufacture deteriorates due to additional assembly steps
Solution Approach 1:
The locking mechanism is divided into distinct functional elements: the secondary locking element as a separate component that can be manufactured independently and then assembled to the contact carrier. This segmentation allows each part to be optimized for manufacturing while maintaining the overall tensile strength requirement.
Solution Approach 2:
The secondary locking element acts as an intermediary component between the plug contact and the contact carrier, providing a simplified interface that enhances tensile strength while facilitating easier assembly through its designed interaction with the other components.
3Ease of operation
If the secondary locking element is designed as a separate displaceable component, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
The secondary locking element is designed to be displaceable relative to the contact carrier, transitioning between different positions during operation. This dynamic capability allows the locking element to be easily operated while its movement is guided by the structural relationship with the contact carrier, minimizing the need for additional complex mechanisms.
Data Source
Figure 1
Figure 2(a)~2(c)
Figure 2(d)~2(f)
AI summary
An electrical connector (1) comprises: a plug contact (3) at one end of a cable (5), a contact carrier (7), a connector housing (9), a primary locking element (11), and a secondary locking element (13). The plug contact is received in the contact carrier, and the contact carrier is received in the connector housing. The primary locking element and the secondary locking element are each configured to secure the plug contact in the contact carrier against removal from the contact carrier by pulling in an axial direction parallel to a longitudinal direction (15) of the cable. The secondary locking element is designed as a separate component that is movable relative to the contact carrier.The connector is configured such that the secondary locking element can be moved from a pre-fixed intermediate position to a fixed end position by moving it in a radially inward direction (17) relative to the contact carrier, wherein the secondary locking element is reversibly detachable in the intermediate position on the contact carrier and wherein the secondary locking element is firmly held on the contact carrier in the end position and rests at least partially against the connector contact in such a way that the connector contact in the contact carrier is secured against removal from the contact carrier by the secondary locking element.