Electrical Connector Secondary Locking Mechanism
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Solution Overview
Problem
Existing electrical connector systems face challenges in miniaturization while maintaining robustness, ease of manufacture, and handling, as they require a balance between compactness and functionality, particularly in the design of plug connectors with secondary locking mechanisms.
Innovation Solution
The proposed electrical connector system incorporates a plug connector with a flexible arm and a secondary locking device featuring a flexible leg and abutment device, allowing for a compact and robust design with primary and secondary locking functions. The secondary locking device is movable between open and closed positions, with a blocking mechanism to prevent unintended unlocking, and is integrated between the terminal cavities and the flexible arm, enabling easier molding and handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If electrical connectors are miniaturized, then the size is reduced, but the robustness and ease of handling deteriorate
Solution Approach 1:
The connector is divided into modular components including a plug connector with terminal cavities, a counter connector, a flexible arm, and a secondary locking device. This segmentation allows each component to be optimized independently for both size and robustness, enabling miniaturization without sacrificing overall reliability.
Solution Approach 2:
The flexible arm and secondary locking device are designed as movable components that can deflect and adapt during insertion and locking. The flexible arm can bend to accommodate misalignment while the secondary locking device moves between locked and unlocked positions, providing robustness through dynamic adaptation rather than rigid fixed structures.
2Reliability
If a secondary locking device is added, then the locking reliability is improved, but the device complexity increases
Solution Approach 1:
The secondary locking device is integrated with the flexible arm as a unified structure rather than separate components. The flexible arm itself forms part of the locking mechanism, combining the functions of connection and locking into a single integrated component, thereby improving reliability without proportionally increasing complexity.
Solution Approach 2:
The secondary locking device is designed to be actuated automatically during the insertion process. As the plug connector is inserted into the counter connector, the flexible arm and locking device self-actuate to engage the locked position without requiring separate manual operation, simplifying the user interface while maintaining enhanced locking reliability.
3Ease of manufacture
If the secondary locking device is positioned between terminal cavities and flexible arm, then the manufacturing ease is improved, but the space availability deteriorates
Solution Approach 1:
The secondary locking device utilizes the third dimension (depth) by positioning it between the terminal cavities and flexible arm in the longitudinal direction. This vertical stacking arrangement allows all components to coexist within the same lateral footprint, enabling easy molding without increasing the connector's overall width or height.
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
This design results in a more compact, robust, and user-friendly electrical connector system that maintains secure locking functionality while being easier to manufacture and handle, with improved scoop-proof functionality and even force distribution across flexible legs, minimizing the risk of damage.
Implementation Method 1
The plug connector housing comprises a flexible arm arranged in a sidewall of the plug connector housing... The secondary locking device comprises a flexible leg with secondary locking means... movable relative to the plug connector housing between an open and closed position
Data Source
Figure 1a~1b
Figure 2~3b
Figure 4a~4b
AI summary
The invention relates to an electrical connector system comprising a plug connector and a second locking device. The plug connector comprises at least one row of terminal cavities for receiving terminals and a plug connector housing having a flexible arm arranged in a sidewall of the plug connector housing, and having primary locking means adapted to provide a primary locking function. The secondary locking device is arranged between an end of the at least one row of terminal cavities and the flexible arm, and has a flexible leg with secondary locking means for providing a secondary locking function. The flexible arm comprises a blocking device and the flexible leg comprises an abutment device adapted to engage with the blocking device for said blocking.