Cylindrical Shim for Electrical Connector Vibration Resistance
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Solution Overview
Problem
Electrical connector assemblies in tractor-trailer systems are prone to corrosion and degradation due to environmental exposure and vibrations, leading to loose connections and loss of electrical contact over time.
Innovation Solution
A cylindrical shim with a expandable sleeve and flange is inserted into the socket to securely hold the plug in place, ensuring a stable connection by allowing the plug to be inserted within the sleeve and maintaining contact with the socket while accommodating the plug's periphery through a gap and providing support with a tapered annular feature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the plug and socket are directly connected without additional securing components, then the device complexity is reduced, but the reliability of the electrical connection deteriorates due to vibrations and environmental exposure
Solution Approach 1:
A cylindrical shim with an expandable sleeve is introduced as an intermediary component between the plug and socket. The shim includes a body portion that fits into the socket and an expandable sleeve that secures the plug, acting as a mediator to prevent direct vibration transmission while maintaining electrical contact.
Solution Approach 2:
The shim is divided into distinct functional segments: a body portion that interfaces with the socket, an expandable sleeve that interfaces with the plug, and a flange for installation. This segmentation allows each part to perform its specific function independently, improving overall connection reliability without excessive complexity.
2Stability of the object's composition
If the cylindrical sleeve is made rigid to securely hold the plug, then the connection stability is improved, but the ease of installation deteriorates due to difficulty in fitting around the plug periphery
Solution Approach 1:
The cylindrical sleeve is designed with dynamic characteristics, allowing it to expand and contract. The sleeve can be compressed during installation to fit over the plug periphery, then expands to securely hold the plug in place, providing both ease of installation and connection stability.
Solution Approach 2:
The physical parameters of the cylindrical sleeve, specifically its diameter, are changed dynamically. The sleeve transitions from a compressed state during installation to an expanded state during operation, enabling it to adapt to the plug periphery and then secure it firmly.
3Manufacturing precision
If the shim includes additional features like flange and tapered annular support, then the manufacturing precision is improved for proper positioning, but the ease of manufacture deteriorates
Solution Approach 1:
The flange and tapered annular support features are pre-formed as integral parts of the shim during manufacturing. The flange provides a preliminary gripping surface for installation, while the tapered annular support pre-establishes the correct positioning geometry, eliminating the need for additional assembly steps.
Data Source
AI summary
A shim for securing an electrical connection of an electrical connection assembly. The shim includes a cylindrical sleeve with opposite proximal and distal ends. The cylindrical sleeve runs from a proximal end of the shim to a distal end of the shim. An interior portion of the cylindrical sleeve is defined by an opening from the proximal end of the shim to the distal end of the shim. The opening allows a plug of the electrical connector assembly to be inserted within the opening of the cylindrical sleeve while the shim is inserted into a socket of the electrical connector assembly to hold the plug securely in the socket of the electrical connection assembly.