Electrical Connector Mating Verification Using Wireless Latch Sensing

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Solution Overview

Problem

Existing electrical connector mating verification systems are either costly due to the need for additional contacts or unreliable due to false verification when latches are not fully mated.

Innovation Solution

A wireless communication-based mated verification system is introduced, where electrical connectors include wireless communication elements that transmit a verification signal only when fully mated, ensuring proper latching and reducing false verification.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If electrical connectors include verification contacts to verify proper connection, then mating verification is achieved, but the cost increases due to additional contacts and redesign

Engineering Contradiction:

Improvemating verificationVSAvoidconnector structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical/electrical verification contact system with a magnetic field-based verification system. The verification contact is replaced by a magnet assembly that generates a magnetic field detectable by a sensor, eliminating the need for additional electrical contacts while achieving the same verification function.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a magnet as an intermediary element between the connector components. The magnet serves as a mediator that transmits verification information through magnetic field interaction with a sensor, replacing the direct electrical contact verification method.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If verification contacts are used to verify proper connection, then mating status can be detected, but false verification occurs when latches are not fully mated

Engineering Contradiction:

Improvemating status detectionVSAvoidverification accuracy

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent implements a feedback mechanism where the sensor continuously monitors the magnetic field generated by the magnet assembly. The verification is only confirmed when the magnetic field signal meets specific criteria, providing feedback that ensures proper latching before verifying mating status.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent requires that the latch mechanism be fully engaged before the verification contacts are mated. This preliminary action ensures that the connector is properly secured before verification occurs, preventing false verification of improperly mated connectors.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If mechanical CPA devices are used to ensure proper latching, then visual and tactile feedback is provided, but the installer may improperly verify actuation

Engineering Contradiction:

Improveinstaller feedbackVSAvoidverification reliability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent replaces mechanical CPA devices with an electronic verification system using magnets and sensors. This substitution eliminates the need for manual visual and tactile verification by the installer, providing automatic electronic verification that cannot be improperly assessed.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The verification system performs self-verification automatically without requiring installer intervention. The sensor detects the magnetic field and determines mating status autonomously, eliminating human error in verification while maintaining ease of operation.

Inventive Principle:

Principle #25Self-service

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 system provides a cost-effective and reliable method for verifying the mated status of electrical connectors, ensuring that all contacts are properly connected and latches are fully engaged.

Implementation Method 1

a wireless communication element configured to transmit a verification signal indicative of the electrical connector being mated with the mating electrical connector

Methodology Applied

Scientific EffectElectromagnetic radiation: Electromagnetic Induction

Data Source

PatentUS20250192479A1Electrical connector having a mating assurance verification

Publication Date: 2025.06.12 TE CONNECTIVITY SOLUTIONS GMBH

AI summary

An electrical connector includes a housing having walls extending between a terminating end and a mating end configured to be mated to a mating electrical connector. The electrical connector includes contacts held by the housing. Each contact extends between a terminating end and a mating end configured to be mated to a mating contact of the mating electrical connector. The electrical connector includes a latching element configured to be latchably coupled to a mating latching element of the mating electrical connector when the housing is fully mated to the mating electrical connector. The electrical connector includes a mated verification device coupled to the housing having a wireless communication element configured to transmit a verification signal indicative of the electrical connector being mated with the mating electrical connector.