Dual-Configurable Electrical Connector System
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Solution Overview
Problem
Existing electrical connector systems require separate sets of connectors for straight and ninety-degree connections, increasing manufacturing costs due to the need for distinct tooling for each configuration.
Innovation Solution
A dual-configurable electrical connector system featuring a male connector with a U-shaped shroud and a female connector with adaptable terminal openings, allowing for both parallel and perpendicular mating configurations using a resilient lock tab and cantilever beam mechanism, which secures the connectors in both orientations with a single set of manufacturing tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate sets of connectors are used for straight and ninety-degree connections, then connector reliability is improved, but manufacturing cost increases
Solution Approach 1:
The connector is designed with a universal structure that can perform both straight and ninety-degree connections through a single component design. The female connector body includes terminal openings that can accommodate male terminals in both parallel and perpendicular orientations, eliminating the need for separate connector sets and reducing manufacturing costs while maintaining connection reliability
2Stability of the object's composition
If separate sets of connectors are used for straight and ninety-degree connections, then connection stability is improved, but device complexity increases
Solution Approach 1:
A single female connector design incorporates terminal openings that accept male terminals in both parallel and perpendicular configurations, reducing the overall system complexity by eliminating the need for multiple specialized connector sets while maintaining stable connections through a unified locking mechanism
Solution Approach 2:
The connector employs a resilient lock tab that can dynamically adapt to secure the male connector in either parallel or perpendicular orientation. The lock tab's flexible nature allows it to engage with the shroud in multiple configurations, providing stable connection across different orientations without requiring separate rigid structures
3Ease of manufacture
If a single set of connectors is used for both straight and ninety-degree connections, then manufacturing cost is reduced, but adapter complexity increases
Solution Approach 1:
The female connector is divided into functional segments including a connector body, terminal openings, and a locking mechanism with resilient lock tabs. This segmentation allows each component to be optimized for its specific function while working together to achieve multi-configuration capability, reducing overall complexity compared to a monolithic design
Solution Approach 2:
The terminal openings in the female connector body are designed with asymmetric geometry that can accommodate male terminals in both parallel and perpendicular orientations. The shroud and lock tab also feature asymmetric designs that enable selective engagement in different configurations, reducing the need for symmetric but overly complex structures
4Ease of operation
If a resilient lock tab mechanism is used, then ease of operation is improved, but manufacturing precision requirements increase
Solution Approach 1:
The lock tab and lock aperture are designed with specific dimensional parameters and tolerances that balance ease of operation with manufacturing precision. The resilient lock tab's deflection characteristics and the aperture's geometry are optimized to provide clear tactile feedback during engagement while accommodating normal variations in manufacturing, reducing the stringency of precision requirements
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
Enables wider application flexibility while reducing manufacturing costs by allowing the same connectors to be used in both straight and ninety-degree connections, ensuring secure engagement with audible and tactile feedback.
Implementation Method 1
The shroud defines a lock aperture and the locking means includes a resilient lock tab configured to engage the lock aperture, thereby securing the connector body to the shroud
Implementation Method 2
The connector body may include a resilient cantilever beam defining the lock tab. The lock tab is proximate a free end of the cantilever beam
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
An electrical connector system (200) having a male and female connector (202, 204). The male connector (202) includes a u-shaped shroud (208) axially surrounding a male terminal (206) having an opening generally perpendicular to the male terminal's longitudinal axis. The female connector (202) includes a female terminal (216) having two openings, one generally parallel with the female terminal's longitudinal axis and another generally perpendicular to that axis. The male and female terminals (116) mate in a parallel configuration having the male terminal axis generally parallel to the female terminal axis or in a perpendicular configuration having the male terminal axis generally perpendicular to the female terminal axis. A connector body holds the female terminal (216). The connector body (230) defines a locking means that releasably secures the connector body (230) to the shroud (208) in both the parallel and perpendicular mating configurations. The locking means may include a triangular shaped lock tab (242) that engages a similarly shaped lock aperture (236).