External Latching Tool for Electrical Contact Retention
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Solution Overview
Problem
Current electrical connector systems in the automotive sector require a significant minimum row spacing and width for contact chambers due to the need for primary latching mechanisms, which limits design flexibility and increases material usage.
Innovation Solution
Implementing a method where primary latching is performed externally by a spring-loaded latching tool that engages from outside the contact chamber wall, allowing for secondary locking only after the tool's removal, thus eliminating the need for special contours for primary latches and reducing the required space and material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If primary latching is performed by chamber hooks on the housing, then reliable contact retention is achieved, but the minimum row spacing and width of contact chambers increase
Solution Approach 1:
The primary latching function is extracted from the contact chamber housing and transferred to an external latching tool. The latching tool engages the contacts from outside the housing through lateral openings, eliminating the need for internal chamber hooks and partition wall structures, thereby reducing the contact chamber width and row spacing requirements
Solution Approach 2:
An external latching tool serves as an intermediary mechanism to perform the primary latching function. This tool temporarily engages the contacts during assembly, provides the necessary latching force, and is subsequently removed, replacing the need for permanent internal latching structures that consume space
2Reliability
If chamber hooks and partition walls are used for primary latching, then contact security is ensured, but material usage increases
Solution Approach 1:
The primary latching function is extracted from the housing structure, eliminating the need for material-intensive chamber hooks and reinforced partition walls. The latching function is instead performed by a separate, removable tool that does not require permanent integration into the housing structure
Solution Approach 2:
The latching tool is used temporarily during the assembly process to secure contacts, then discarded (removed) after its function is complete. This eliminates the need for permanent latching structures that would consume material throughout the product lifecycle, achieving material savings without compromising contact security during assembly
3Reliability
If special contours for primary latches are designed into each contact and contact chamber, then reliable latching is achieved, but design flexibility and structural freedom are reduced
Solution Approach 1:
The primary latching function is extracted from the contact and contact chamber designs, eliminating the need for specialized contours, undercuts, or features in these components. The latching tool provides the latching function externally, allowing contacts and chambers to maintain simple, versatile geometries suitable for various applications
Solution Approach 2:
The external latching tool serves as a universal mechanism that can accommodate different contact types and configurations without requiring custom latching features in each contact design. This enables greater design flexibility and versatility in contact geometry while maintaining reliable latching through the standardized external tool
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
This approach reduces the minimum row spacing and width of contact chambers, saving space and material while maintaining secure secondary locking, and does not interfere with mechanical or electrical testing.
Implementation Method 1
The latching tool (12) has two rows of latching arms (13a, 13b) with spring elements (16) for elastic prestressing of the latching arms (13a, 13b) in the engagement direction (7a)
Data Source
Figure 1a~1e
Figure 2
Figure 3a~3c
AI summary
In a method for secondarily locking at least one electrical contact (2) which is inserted into a contact chamber (7) and is primarily latched therein, the at least one electrical contact (2) is, according to the invention, primarily latched in its contact chamber (7) by means of an external latching tool (12) which engages in the contact chamber (7) through a lateral wall opening (11) in the contact chamber outer wall (10) from outside, and the electrical contact (2) is then secondarily locked in its contact chamber (7) before the external latching tool (12) is removed again. The associated contact latching system for an electrical plug connection comprises at least one electrical contact (2) which has an undercut (6) for a primary latching means, a contact chamber housing (1) which has at least one contact chamber (7) for insertion of the electrical contact (2), and at least one locking element (17) for secondarily locking the inserted electrical contact (2) against the fitting direction (3), wherein, according to the invention, a contact chamber outer wall (10) of the contact chamber (7) has a lateral wall opening (11) through which the undercut (6) in the inserted contact (2) is accessible from the outside.