Guided Plug Connector with Tilting Collar for Ice Pressure
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Solution Overview
Problem
Existing multiple plug connectors fail to maintain functionality and secure connections under increased fluid pressure caused by temperature fluctuations, such as ice pressure, which can lead to misalignment and sparking of electrical contacts.
Innovation Solution
The design features a separate and modular structure with a collar that allows for a predetermined tilting angle of the plug parts, ensuring correct alignment of electrical contacts and incorporating a sealing element to prevent play and sparking, while distributing pressure evenly across components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the plug connector is assembled from fewer individual parts, then the device complexity is reduced, but the ability to absorb fluid pressure and ice pressure is decreased
Solution Approach 1:
The plug connector is divided into multiple independent parts including a first plug part, a second plug part, a fluid connector, and a spectacle part. This segmentation allows each component to independently absorb and distribute pressure forces, particularly from ice formation, preventing any single point of failure while maintaining overall structural integrity under pressure.
2Device complexity
If the electrical connections and fluid connection are integrated into a single assembly, then the device complexity is reduced, but the force from fluid pressure is transmitted to electrical connections causing misalignment and sparking
Solution Approach 1:
The electrical connections and fluid connection are separated into distinct components. The fluid connector handles fluid pressure independently while the spectacle part houses electrical connections separately. This extraction prevents transmission of fluid pressure forces to electrical contacts, eliminating misalignment and sparking risks while maintaining functional integration through coordinated assembly.
3Manufacturing precision
If the plug parts are rigidly fixed without tilting capability, then the alignment precision is improved, but the ability to accommodate insertion angle variations is reduced
Solution Approach 1:
The collar is designed with a controlled tilting capability that allows the plug parts to accommodate insertion angle variations up to a predetermined limit. Once inserted, the collar maintains precise alignment of electrical contacts through its geometric constraints. This dynamic design provides both insertion flexibility and operational precision without requiring perfect alignment during assembly.
4Ease of operation
If the electrical contact pins are aligned directly with the windows of contact sockets, then the plugging operation is simplified, but incorrect insertion at angles can cause misalignment and sparking
Solution Approach 1:
The electrical contact pins are deliberately offset from direct alignment with the contact socket windows by 4° to 8°. This preliminary misalignment acts as a protective measure that prevents incorrect angled insertion, as the offset geometry blocks improper engagement. Correct insertion is still achieved through the collar's guidance, which compensates for the offset and ensures proper contact alignment.
Data Source
Figure 1a~1f
Figure 2a~2d
Figure 3a~3e
AI summary
The invention relates to a multi-line plug connector (1) for connecting two heated fluid lines via a plugging process, comprising a female plug part (2) that is/can be detachably connected to a male plug part (3) along a plugging axis (X), wherein each plug part (2, 3) has a fluid connection (35, 35a, 35b) and two electrical connections. Each plug part (2, 3) comprises a two-part plug housing formed of a base part (5) and a cover part (6) which can be connected to one another and surround an internal space (I) in which an eyeglass-shaped part (8) is accommodated. The eyeglass-shaped part (8) comprises two guide channels (9) extending along the plugging axis (X) for receiving the electrical lines provided with electrical contacts, and the guide channels (9) are connected to one another via at least one cross-piece (10), wherein the cross-piece (10) is frictionally and/or interlockingly connected to an engaging means of the base part (5), protruding into the internal space (I), in such a way that the eyeglass-shaped part (8) is secured on the base part (5) against movements along and/or transverse to the plugging axis (X). The eyeglass-shaped part (8) accommodates a tubular fluid connector (7) which is frictionally and/or interlockingly connected to the eyeglass-shaped part (8) against movements along the plugging axis (X), wherein the tubular fluid connector (7) can be connected with the heatable fluid line at one end and is designed as a plug connector part at an opposing end of the fluid connector (7).