Connector Secondary Lock Thermal Embossing
Solution Overview
Problem
Existing connectors with flat contacts face challenges in achieving a simple, reliable, and secure plug connection with primary and secondary locking mechanisms that can withstand high mechanical loads without being easily released, and are complex and costly to manufacture.
Innovation Solution
A connector design where the secondary locking means with thermally deformable holding arms are permanently attached to the contact carrier by thermal embossing, ensuring they cannot be removed from their locking position, and primary locking means are used to secure flat contacts within the contact carrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a secondary locking means with detachable holding arms is used, then the connector can be assembled and disassembled, but the locking can be unintentionally released and the structure is complex and expensive to manufacture
Solution Approach 1:
The patent replaces the mechanical detachable holding arms with a permanent thermal bonding connection. The holding arms are thermally deformable and are permanently attached to the contact carrier through thermal embossing, eliminating the need for mechanical attachment mechanisms while maintaining locking reliability.
Solution Approach 2:
The patent changes the physical state of the holding arms by making them thermally deformable. This allows the holding arms to be permanently bonded to the contact carrier through thermal embossing, transforming them from detachable mechanical components to permanently fixed structural elements that cannot be unintentionally released.
2Reliability
If traditional primary and secondary locking mechanisms are used, then the connector can secure flat contacts, but the manufacturing process is complex and costly
Solution Approach 1:
The patent merges the secondary locking means with the contact carrier by permanently bonding the holding arms to the contact carrier through thermal embossing. This integration eliminates separate assembly steps and reduces manufacturing complexity while maintaining reliable contact securing.
Solution Approach 2:
The patent replaces complex mechanical attachment mechanisms with a simplified thermal bonding process. The thermally deformable holding arms are permanently attached to the contact carrier through thermal embossing, significantly simplifying the manufacturing process while ensuring reliable contact securing.
3Strength
If detachable holding arms are used in the secondary locking means, then the locking mechanism can be assembled, but it cannot withstand high mechanical loads securely
Solution Approach 1:
The patent changes the physical properties of the holding arms by making them thermally deformable. This allows them to be permanently bonded to the contact carrier through thermal embossing, creating a rigid, load-bearing structure that can securely withstand high mechanical loads while maintaining assembly simplicity.
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 provides a secure, permanent, and cost-effective connection that prevents unintentional release of the secondary locking mechanism, ensuring durability and stability under mechanical loads, while simplifying assembly and manufacturing processes.
Implementation Method 1
the holding arms of the secondary locking means can be thermally deformed in their locking position so that they can no longer be pulled out of the contact carrier or the locking position of the secondary locking means can no longer be solved
Implementation Method 2
the holding arms of the secondary locking means with thermally deformable holding arms are permanently attached to the contact carrier by thermal embossing
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
According to the invention, a connector is therefore proposed comprising a contact carrier, at least two flat contacts and a secondary locking means with retaining arms, wherein the contact carrier is provided with openings for inserting a secondary locking means for securing the flat contacts in the contact carrier and the flat contacts have primary locking means,in which the respective flat contact rests on a corresponding locking element in the contact carrier (thereby creating a primary locking mechanism), and wherein each flat contact furthermore has a locking opening for through-mounting the secondary locking element, and wherein the secondary locking element, with its retaining arms, is inserted into the openings of the contact carrier to fix the flat contacts in its locking position, and its retaining arms protrude through the locking openings of the flat contacts and are inseparably connected to the contact carrier (especially at its end sections).