Latchable Contact Side Wall Overlap Protects Locking Lance
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Solution Overview
Problem
Conventional plug connection elements with protruding primary locking lances are prone to damage from external forces during manufacturing, handling, and when latched in contact chambers, especially due to forces from cable tension, leading to plastic deformation.
Innovation Solution
The primary locking lance is protected by having side walls of the contact box protrude outward beyond the upper wall plane, overlapping the lance to prevent excessive outward bending, with both side walls overlapping the lance to counteract forces from both sides and prevent twisting, while maintaining a minimal cross-sectional area for easy insertion and avoiding damage during insertion and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the primary locking lance protrudes outward from the contact box, then the contact can be latched in the contact chamber, but the primary locking lance is vulnerable to damage from external forces during manufacturing, handling, and cable tension
Solution Approach 1:
The side walls of the contact box are merged with protective elements that overlap the primary locking lance. The side walls extend beyond the upper wall plane and laterally adjoin the lance, combining the structural function of the contact box with the protective function against external forces.
Solution Approach 2:
The side walls are positioned to preemptively counteract external forces before they can damage the primary locking lance. By overlapping the lance laterally, the side walls provide preliminary protection against forces acting from above, below, or laterally during manufacturing and handling, and against cable tension forces during operation.
2Strength
If the side walls protrude outward beyond the upper wall plane to protect the primary locking lance, then the lance is protected against damage, but the cross-sectional area of the contact increases
Solution Approach 1:
The side walls protrude outward only in the specific area laterally adjoining the primary locking lance, rather than extending uniformly around the entire contact box. This localized protrusion provides protection exactly where needed while minimizing the overall increase in cross-sectional area and maintaining ease of insertion.
3Reliability
If both side walls overlap the primary locking lance, then the lance is protected against forces from both sides and twisting, but the device complexity increases
Solution Approach 1:
The protective function is merged into the existing side walls of the contact box rather than adding separate protective components. The side walls serve dual purposes: containing the contact box structure and protecting the primary locking lance, thereby avoiding increased device complexity.
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 effectively prevents excessive plastic deformation of the primary locking lance by providing a form-locked protection against lateral and outward forces, ensuring the lance remains functional and minimizes the risk of damage during handling and insertion into contact chambers.
Implementation Method 1
The primary locking lance protrudes resiliently diagonally outward from the upper wall of the contact box... the primary locking lance first compresses until a suitable recess in the contact chamber is reached, in which the primary locking lance then decompresses and thus latches the contact
Implementation Method 2
an outside edge of this side wall overlapping a side edge of the primary locking lance in such a way that it counteracts outward bending of the primary locking lance in a form-locked manner
Data Source
AI summary
A contact is provided for latching in a contact chamber of a plug connection element. The contact has a contact box having an upper wall, a lower wall, and two opposing side walls. A primary locking lance protrudes resiliently diagonally outward from the upper wall. To protect the primary locking lance against harmful plastic deformations due to externally attacking forces, at least one of the side walls, in an area laterally adjoining the primary locking lance, is configured to protrude outward beyond a plane of the upper wall. An outside edge is bent toward the primary locking lance, so that it overlaps a side edge of the primary locking lance so that it counteracts outward bending of the primary locking lance in a form-locked manner.