Fast-Separable Electrical Connector With Elastic Housing
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Solution Overview
Problem
Existing electrical connectors for high-current vehicle applications, such as connecting electrical accumulators to drive devices, are not suitable for quick and tool-free separation and reconnection, as they require complex setups, are prone to external damage, and pose safety risks due to exposed electrical components.
Innovation Solution
A fast-separable electrical connector design featuring a pot-shaped contact element with slots, an insulating sleeve, and an elastic housing that provides a secure and sealed connection, allowing for easy handling and quick disconnection without tools, while preventing exposure to external influences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional battery terminals with clamping screws are used, then reliable electrical connection is achieved, but quick disconnection without tools is not possible
Solution Approach 1:
The connector is divided into separate coupling parts (first and second coupling parts) that can be quickly connected and disconnected. Each coupling part contains contact elements that engage with each other, allowing tool-free assembly and disassembly while maintaining reliable electrical connection during operation.
Solution Approach 2:
The connector design includes self-aligning and self-latching features where the coupling parts automatically engage and secure to each other without requiring external tools or complex assembly procedures. The contact elements are positioned and held in place through the structural design of the housings themselves.
2Ease of operation
If electrical contact elements are freely accessible for connection, then easy connection is achieved, but safety risks from electric shock increase
Solution Approach 1:
The contact elements are nested within protective housings that enclose them during storage and transport. When connected, the contact elements engage within the overlapping housing structure, maintaining protection while enabling electrical connection. The housing structure provides physical barriers that prevent direct access to live contacts.
Solution Approach 2:
The housing structure acts as a protective shell that encloses the contact elements. The housing provides insulation and physical protection, preventing direct contact with exposed electrical components while allowing the connector to function properly when mated.
3Device complexity
If clamping devices are exposed to moisture and dirt, then simple design is maintained, but electrical connection reliability deteriorates
Solution Approach 1:
The contact elements are nested within the housing structure, which provides protection from environmental contaminants. The overlapping housing design creates a enclosed space that shields the electrical contacts from moisture and dirt while maintaining the simplicity of the overall connector design.
Solution Approach 2:
The housing structure serves as a protective barrier that shields the electrical contact elements from moisture and contamination. This simple housing design provides environmental protection without requiring complex sealing mechanisms or additional protective components.
4Adaptability or versatility
If multiple separate components are used in connectors, then adaptability is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The connector design combines multiple functions into integrated housing structures. Each coupling part integrates contact elements, insulation, and protective housing into a single assembly, reducing the total number of separate components while maintaining the necessary adaptability for electrical connection.
Solution Approach 2:
The housing structure serves multiple functions simultaneously: providing mechanical protection, electrical insulation, structural support for contact elements, and environmental sealing. This multi-functionality reduces the need for separate components for each function.
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 connector ensures a safe, secure, and space-efficient electrical connection that can withstand vibrations and acceleration forces, with a simple and cost-effective production process, and provides effective protection against moisture and dirt without additional sealing measures.
Implementation Method 1
The inner sheath surface of the insulating sleeve is spaced apart from the outer sheath surface of the sheath of the electrical contact element. This measure ensures that adjacent electrical contact tongues, separated from each other by the slots, can move outwards when a second contact element, which rests against the inner contact tongues, is inserted.
Implementation Method 2
This housing is manufactured by overmolding with a plastic material. Due to the overmolding process, a sheath is created that completely surrounds all electrically conductive parts of the first contact element as well as part of the insulation of the electrical conductor
Implementation Method 3
The second housing is preferably made of an elastic, and particularly preferably a rubber-elastic, material. Due to the particularly good sealing effect achieved in the overlapped state, external, negative influences on the electrical contact between the first and second contact elements are effectively prevented
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a electrical plug-in connection (100) that can be quickly disconnected and comprises: a first coupling part (101), which comprises a first electrical contact element (1), a connection cable (10), an insulation sleeve (9), and a first housing (13); and a second coupling part (102), which has a second electrical contact element (7), onto which the first electrical contact element (1) can be slid, and a second housing (16), which together with the second electrical contact element (7) forms an annular space (28), into which the first housing (13) can be inserted.