Floating Insulator Assembly for Shock-Tolerant Connector Mating

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Connectors on hard bases such as busbars, enclosures, or PCBs are prone to reduced longevity and fewer mating cycles due to shock, vibration, and misalignment during mating.

Innovation Solution

A floating insulation accessory with flexible and rigid fixations that provide concentric flotation and mechanical support within cutouts, allowing toolless assembly and resistance to shock, vibration, and misalignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If connectors are fixed rigidly on hard bases, then assembly precision is improved, but shock and vibration damage increases

Engineering Contradiction:

Improveassembly precisionVSAvoidshock and vibration damage

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The insulation accessory is designed with a floating mechanism that allows dynamic movement within the cutout. The flexible fixations enable the accessory to move with shock and vibration rather than remaining rigidly fixed, converting static rigid mounting into dynamic adaptive mounting that absorbs mechanical stress.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent changes the mechanical state parameter from rigid fixed to floating movable. By introducing flexible fixations with elastic properties, the system transitions from a rigid connection state to a compliant floating state, allowing the connector to accommodate shock and vibration while maintaining electrical connection.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If traditional fixed insulation accessories are used, then manufacturing simplicity is maintained, but connector longevity decreases

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidconnector longevity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The floating insulation accessory incorporates flexible fixations that provide dynamic movement capability, significantly improving connector longevity by absorbing shock and vibration. The design maintains manufacturing simplicity through integrated molding of the flexible fixations into the insulation accessory body, requiring no additional assembly steps.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent employs flexible fixations made from elastomeric or polymeric materials that form compliant elements within the rigid insulation accessory. These flexible components act as shock-absorbing elements while maintaining structural integrity, extending connector life without complicating manufacturing.

Inventive Principle:

Principle #30Flexible shells and thin films

3Ease of operation

If toolless assembly is implemented, then ease of operation is improved, but assembly precision may worsen

Engineering Contradiction:

Improveease of assemblyVSAvoidassembly precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The floating insulation accessory features self-aligning flexible fixations that automatically position themselves during insertion into the cutout. The elastic deformation of these fixations during assembly provides self-centering action, ensuring concentric flotation and precise positioning without requiring tools or complex alignment procedures.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent utilizes elastic deformation parameter changes in the flexible fixations during the assembly process. As the accessory is inserted, the flexible elements deform elastically to accommodate slight misalignments, then spring back to establish precise concentric positioning, achieving both toolless assembly and high assembly precision.

Inventive Principle:

Principle #35Parameter changes

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

Enhances connector longevity and allows high mating cycles while maintaining electrical connections under varying conditions.

Implementation Method 1

an insulation sleeve portion comprising two or more flexible fixations on an outside surface of the insulation sleeve portion; a mating interface portion comprising two or more rigid fixations extending radially from an outside surface of the mating interface portion

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

Extrusions of the flexible fixations are arranged to provide concentric flotation of the insulation accessory inside the cutout

Methodology Applied

Scientific EffectBuoyancy: Archimedes' Principle (Buoyancy)

Data Source

PatentEP4704264A1One-way toolless assembly insulator

Publication Date: 2026.03.04 ITT CANNON

Figure 1A
Figure 1B
Figure 2

AI summary

An insulation accessory, comprises an insulation sleeve portion comprising two or more flexible fixations on an outside surface of the insulation sleeve portion; a mating interface portion comprising two or more rigid fixations extending radially from an outside surface of the mating interface portion; and two or more latching hooks extending inward from an inside surface of the insulation sleeve portion, wherein the rigid fixations and extended edges of the flexible fixations are arranged to push against surfaces of a hard base around a cutout to maintain the insulation accessory inside the cutout, and extrusions of the flexible fixations are arranged to provide concentric flotation of the insulation accessory inside the cutout.