Flush-Mounted Electrical Connector Cap Design

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Solution Overview

Problem

Conventional electrical connectors have caps that protrude, making them unsuitable for flush mounting, are not interchangeable with existing panels, and can be dislodged by axial or angular forces on the plug, requiring replacement of panels for compatibility.

Innovation Solution

An electrical connector design featuring a cap that engages retention features on the housing to secure it flush with the panel, allowing compatibility with standard panel sizes and resisting dislodgment forces, with a design that maintains the connector's overall envelope and allows for color matching with existing panels.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the cap protrudes outward from the connector body to secure the plug, then the plug interface is accessible and the cap can retain the plug, but the overall envelope of space increases and the connector cannot be flush mounted

Engineering Contradiction:

Improveplug accessibilityVSAvoidconnector envelope

Core Design Contradiction:

Ease of operationVSVolume of moving object

Solution Approach 1:

The cap is redesigned to engage with retention features on the connector body in a way that positions the front face of the cap flush with the panel surface. The retention features extend into the connector body interior, allowing the cap to be secured without protruding outward, thus solving the contradiction between plug accessibility and connector envelope volume.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The cap is nested within the connector body envelope, with the retention features positioned inside the connector body. This allows the cap to be securely retained while maintaining a compact overall size that enables flush mounting to the panel surface.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Shape

If the cap is designed with specific contours to match a panel, then the connector achieves cosmetic appearance and protection, but the cap is not interchangeable with existing panels

Engineering Contradiction:

Improvecap contour matchingVSAvoidpanel compatibility

Core Design Contradiction:

ShapeVSAdaptability or versatility

Solution Approach 1:

The retention features are designed with standardized dimensions and configurations that can engage with corresponding features on different panel types. This universal design allows the same cap to be interchangeably mounted on existing panels with standard window openings, achieving both cosmetic matching and broad panel compatibility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The cap design separates the cosmetic contour features from the retention mechanism. The front face can be customized for cosmetic matching while the retention features use standardized interfaces, allowing the cap to maintain both aesthetic appearance and interchangeability across different panel applications.

Inventive Principle:

Principle #1Segmentation

3Ease of operation

If the cap mechanically engages the plug with internal coupling mechanisms, then the plug is retained within the plug interface, but axial or angular forces on the plug can dislodge the cap from the electrical connector

Engineering Contradiction:

Improveplug retentionVSAvoidcap security

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

Retention features are introduced as intermediary elements between the cap and the connector body. These features act as mechanical mediators that transfer and distribute forces, preventing direct transmission of axial or angular plug forces to the cap-retention interface, thereby preventing cap dislodgment while maintaining plug retention.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The retention features are designed to preemptively counteract dislodging forces by providing mechanical engagement that resists axial and angular loads before they can cause cap dislodgment. The features create a force-distributing structure that cushions against unexpected plug manipulation forces.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Ease of manufacture

If a larger opening in the panel is created to accommodate the protruding cap, then the connector can be mounted, but the panel structure is modified and existing standard openings cannot be used

Engineering Contradiction:

Improveconnector installationVSAvoidpanel opening size

Core Design Contradiction:

Ease of manufactureVSArea of stationary object

Solution Approach 1:

The cap design changes the mounting parameters by positioning the retention features inside the connector body rather than requiring external protrusion. This parameter change allows the cap to be mounted through existing standard panel openings without requiring enlarged openings, maintaining compatibility with existing panel structures.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS8057249B1Electrical connector with slim-line cap

Publication Date: 2011.11.15 COMMSCOPE TECHNOLOGIES LLC

AI summary

An electrical connector includes a mating end having a plug interface. The mating end has a retaining surface defined around the plug interface. At least one retention feature is provided on the retaining surface. A cap is provided having a plurality of sides and a front face. An opening extends through the front face. The cap is mounted to the mating end so that at least one of the plurality of sides of the cap engages the at least one retention feature to secure the cap to the mating end. The plug interface is accessible through the opening in the cap. The electrical connector is configured to be rear mounted to a panel so that the plug interface is accessible through an opening in the panel and the front face of the cap is capable of positioning flush with a front face of the panel.