DC Plug Connector Resilient Collar Design
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Solution Overview
Problem
Existing DC plug and socket connectors face issues with inconsistent standards, leading to potential damage and poor current supply due to incompatible plug sizes and manufacturing tolerances, resulting in electric arcing and unreliable contact.
Innovation Solution
A pin connector assembly with an annular resilient collar that compresses radially to maintain electrical contact between the plug and socket, accommodating dimensional variations by fitting over the pin or within the bore, ensuring a secure and effective connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rigid pin connector is used, then manufacturing precision can be maintained, but reliability deteriorates due to manufacturing tolerances causing poor contact or electric arcing
Solution Approach 1:
The patent transforms the rigid pin connector into a dynamic system by adding a resilient collar that can radially expand and contract. This dynamic element compensates for manufacturing tolerances and dimensional variations between plugs and sockets, ensuring reliable electrical contact without requiring high manufacturing precision.
Solution Approach 2:
The resilient collar changes its dimensional parameters (radial size) in response to the fit between plug and socket. When the plug bore is larger than the pin, the collar expands to fill the gap; when dimensions match, the collar maintains its normal size. This parameter change allows the connector to adapt to various manufacturing tolerances while maintaining reliable contact.
2Reliability
If a resilient collar is added to accommodate dimensional variations, then reliability improves, but device complexity increases
Solution Approach 1:
The patent merges the resilient collar with the existing pin connector structure, integrating the compensation mechanism into the pin itself rather than adding a separate component. The collar is fitted over the pin and forms a unified assembly, reducing overall complexity while maintaining the reliability benefits.
Solution Approach 2:
The resilient collar is designed to automatically adjust to dimensional variations without requiring external control or adjustment mechanisms. It self-regulates its radial size based on the fit between plug and socket, eliminating the need for complex control systems or manual adjustments.
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 provides a reliable and efficient electrical connection by allowing 2.1 mm and 2.5 mm plugs to work with a 2.1 mm pin, preventing arcing and ensuring consistent power supply, even with manufacturing tolerances, by using a tubular radially compressible spring made of resilient materials like copper or stainless steel.
Implementation Method 1
an annular resilient collar adapted to fit either over the pin of the socket or within the bore of the plug and which compresses radially inwards when the circumference of the bore and the pin are of essentially equal size
Data Source
AI summary
A pin connector assembly comprising a socket (11) adapted to receive a cylindrical electrical plug (12), the plug having a central longitudinal bore (17), the socket being in the form of an insulated housing having a cylindrical receptacle (13) with a pin (14) located in the centre thereof, said pin (14) being adapted to be located in the bore (17) of the plug when the plug and the socket are in mating connection, the assembly further comprising an annular resilient collar (20) adapted to fit either over the pin (14) of the socket or within the bore (17) of the plug and which compresses radially inwards when the circumference of the bore and the pin are of essentially equal size and which remains in an expanded configuration when the circumference of the bore (17) is greater than the circumference of the pin (14), thus maintaining electrical contact between the electrical plug (12) and the socket (11).