High-Current Connector With Elastic Latch
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Solution Overview
Problem
Existing power distribution units (PDUs) face challenges in efficiently managing high current inputs exceeding 30 Amps, requiring connectors that are compact, reliable, and adaptable for various power environments while ensuring secure and efficient cable management.
Innovation Solution
A high-current connector design featuring a socket with elastic tab fasteners, inverted tooth structure, and a handle with a U-shaped groove, allowing for secure connection and easy installation, compatible with 3-pin, 4-pin, and 5-pin plugs, and enabling cable connection during PDU installation rather than production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional connector design is used for high current inputs exceeding 30 Amps, then the connector can handle the current, but the size becomes large and the structure becomes complex
Solution Approach 1:
The connector is divided into separate components: a socket portion with conductive inserts, a plug portion with corresponding receptacles, and a latching mechanism. This segmentation allows each component to be optimized independently for high current handling while keeping the overall structure manageable and less complex.
Solution Approach 2:
The conductive inserts are nested within the socket and plug bodies, with the plug inserting into the socket. The latching mechanism is integrated within the handle structure. This nesting reduces the overall footprint and complexity while maintaining the ability to handle high currents through properly sized conductive elements.
2Volume of moving object
If a compact connector design is used, then the size is reduced for narrow spaces, but the reliability of secure connection may be compromised
Solution Approach 1:
The latching mechanism incorporates a movable latch that transitions between engaged and disengaged states, providing dynamic security. The elastic tab fasteners provide flexible engagement that adapts to slight misalignments while maintaining secure connection. This dynamic approach ensures reliable connection in a compact form factor.
Solution Approach 2:
The latching mechanism combines multiple functions: the latch provides mechanical interlocking, the elastic tabs provide engagement force and alignment, and the hasp provides additional securing. By merging these functions into an integrated latching system, the connector achieves high connection security in a compact design without requiring separate complex mechanisms.
3Reliability
If cable connection is performed during PDU production, then the power distribution is reliable, but the installation time and complexity increase
Solution Approach 1:
The conductive inserts are pre-installed and positioned within the socket and plug bodies during manufacturing. The socket is pre-configured with the correct conductive elements in place. This preliminary action ensures proper electrical connections are established before field installation, maintaining reliability while reducing installation time since cables can be connected quickly by simply plugging in the pre-configured unit.
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 provides a compact, reliable, and efficient solution for high-current power distribution, ensuring secure cable management and preventing conductive insert disengagement, suitable for narrow spaces and various power configurations.
Implementation Method 1
Elastic tab fasteners are arranged to secure the socket within the socket opening of the PDU
Data Source
AI summary
A connector includes a socket configured to be secured within a socket opening of a power input. A socket head has a plurality of plug insert receptacles. Each plug insert receptacle receives a conductive insert. The conductive insert connects with a cable that extends from the plug insert receptacle through and out of the socket. A plug contains a base. A head of the base has a plurality of plug insert units. Each plug insert unit receives a conductive insert that connects with a cable that extends out the base of the plug. A handle covers the base. The handle and the base are fixed and connected by a positioning device that includes an inverted tooth structure. The socket and plug when connected are secured in place by an elastic hasp.