U-Shaped Connector Shield for Mounting Rail Protection
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Solution Overview
Problem
High-current connectors on mounting rails in harsh industrial environments are prone to damage, leading to connector failure and potential safety hazards due to lack of effective protection.
Innovation Solution
A U-shaped mudguard with angled side surfaces and recesses is designed to cover and protect connectors on a mounting rail, featuring a fixing edge that engages with the rail's undercut to prevent dislodgment, and can be secured using double stud bolts or press-in screws for effective and cost-efficient protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connectors are mounted on a mounting rail in harsh industrial environments, then electrical connectivity is achieved, but the plastic housings are prone to mechanical damage leading to connector failure
Solution Approach 1:
The patent applies beforehand cushioning by providing a protective cover that surrounds the connector housing before mechanical damage can occur. The cover is designed to absorb and distribute mechanical impacts, protecting the vulnerable plastic housing from damage in harsh industrial environments.
Solution Approach 2:
The protective cover functions as a protective shell that envelops the connector housing. This shell structure provides mechanical protection while maintaining a compact design that does not interfere with the connector's electrical function.
2Object-affected harmful factors
If a protective cover is added to protect connectors, then mechanical protection is improved, but device complexity increases
Solution Approach 1:
The protective cover is designed as a separate, modular component that can be independently manufactured and assembled with the connector. This segmentation allows the protection function to be added without redesigning the entire connector system, thereby limiting the increase in device complexity.
Solution Approach 2:
The protective cover serves multiple functions: it provides mechanical protection, can facilitate mounting to the rail system, and may provide structural support. By combining multiple functions into a single component, the overall system complexity is minimized while achieving comprehensive protection.
3Object-affected harmful factors
If a closed housing is used to protect connectors, then mechanical protection is improved, but manufacturing cost and complexity increase
Solution Approach 1:
Rather than manufacturing a completely closed housing as a single complex piece, the protective cover is designed as a segmented structure that can be formed from a flat sheet through stamping and bending operations. This segmentation simplifies the manufacturing process while maintaining protective functionality.
Solution Approach 2:
The protective cover transitions from a flat sheet state to a three-dimensional protective structure through forming operations. This parameter change allows the same material to provide comprehensive protection without requiring complex assembly of multiple parts, thereby maintaining manufacturing simplicity.
4Reliability
If the protective cover is secured with multiple fastening elements, then attachment reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The protective cover integrates mounting features directly into its structure, merging the fastening function with the protective cover itself. This eliminates the need for separate, complex fastening mechanisms while ensuring reliable attachment to the rail system through features like fixing edges that engage with the rail structure.
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a protective plate for at least one plug connector attached to a mounting rail, said protective plate having a substantially U-shaped basic form with a closed main surface (2) and side surfaces (3, 3') angled at approximately 90° to the main surface, wherein a securing region (5, 5') is angled at approximately 90° to the side surfaces (3, 3'), said securing region (5, 5') having at least one hole (6), and wherein an abutting region (7, 7') is angled at approximately 90° to the side surfaces (3, 3'), said securing region (5, 5') and the corresponding abutting region (7, 7') being positioned approximately perpendicular to one another. The system, formed by protective plate, a mounting rail (8) and at least one plug connector (9), is optimally coordinated.