Electrical Connector Safety Locking for Compact Reliable Mating
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Solution Overview
Problem
Existing electrical connectors for motor vehicles and mobile systems are not compact enough, making them difficult to design, manufacture, store, and transport, and they lack robustness and reliability in the mating process.
Innovation Solution
A connector design that incorporates a compact Safety Locking System (SLS) with a 'U' shape and pivots, which automatically locks upon mating and minimizes involuntary unlocking during transport or storage, allowing for ergonomic manufacturing and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional locking system is used in connectors, then the connector provides basic locking functionality, but the connector size increases and compactness is reduced
Solution Approach 1:
The patent combines the locking system with the housing structure itself, where the locking protrusions are integrated into the housing walls rather than being separate components. This merging of functions allows the locking mechanism to be part of the existing housing geometry, providing reliable locking while maintaining compact connector dimensions
Solution Approach 2:
The housing structure serves multiple functions: it provides structural support, guides the connector during insertion, and simultaneously provides the locking mechanism through integrated protrusions. This multi-functionality eliminates the need for additional dedicated locking components, reducing overall connector volume while maintaining locking reliability
2Volume of moving object
If the connector is designed to be compact, then manufacturing and storage become easier, but the locking system may be more prone to involuntary movement
Solution Approach 1:
The locking protrusions are designed with asymmetric geometries that provide stable engagement in the locked position while preventing involuntary movement. The specific shapes and orientations of the protrusions create a mechanically stable configuration that resists accidental disengagement, even in the compact connector design
Solution Approach 2:
Instead of using a traditional latch that must be actively engaged, the design uses passive locking protrusions that automatically engage during insertion. The locking action occurs naturally through the insertion movement itself, reversing the conventional approach where a separate locking action is required, thereby improving both compactness and reliability
3Reliability
If multiple locking mechanisms are added to prevent accidental unlocking, then reliability improves, but device complexity increases
Solution Approach 1:
The anti-unlocking protection is merged into the same locking protrusions that provide the primary locking function. The same structural features that prevent accidental unlocking also serve as the locking mechanism, eliminating the need for separate anti-unlocking components and reducing overall system complexity
Solution Approach 2:
The locking system is designed to be self-servicing, where the insertion movement automatically performs both the locking action and the anti-unlocking protection setup. The connector self-locks and self-protects against accidental unlocking through its geometric design, without requiring additional mechanisms or complex control systems
Data Source
Figure 1a~2c
Figure 3a~4
Figure 5a~6c
AI summary
Disclosure relates to a connector to be mated and unmated with a counter-connector through(M1) insertion and extraction(M2) movement. Said connector(1) comprises a safety locking system(3), called "SLS", that bears a SLS locking edge(39) and is rotably mobile(R31) around an axis(A31) perpendicular to insertion movement, between: - an unlocking position, allowing extraction movement(M2), and - a locking position, preventing said extraction movement(M2) an abutment of SLS locking edge(39) with a counter-connector surface(9132) that is transverse to said extraction movement(M2). SLS has a "U" shape, with pivots(31) on both wings that are inserted in connector housing transversally to the insertion movement. Wings have a prelocking latch(32), maintaining SLS in unlocking position until insertion movement M1, which automatically frees prelocking latch. SLS is retained in locking position by an elastic latch arm(33) abutting against an internal face of said roof, preventing unlocking rotation(R31) of said SLS. SLS is unlocked by back rotation(R32) enabled by pressing on latch arm.