Hinged Electric Connector With Ball Joints For Vibration Resistance
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Solution Overview
Problem
Existing electrical connectors in military applications face challenges with reliability due to vibrations, dust, and oil deposits, leading to insecure connections and tedious assembly processes, especially when using flexible wires or cables with minimum lengths greater than 30 mm.
Innovation Solution
An electrical connector design featuring a first and second base with hinged attachments and rigid electrical connection members with ball joints or sockets, allowing for relative movement and secure articulation, and optionally using an elastic and insulating silicone block for assembly, eliminating the need for tedious welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding operations are used to connect electrical wires to the board, then reliable electrical connections are achieved, but the assembly process becomes tedious and time-consuming
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical insertion system where connectors are directly inserted into receptacles. The electrical connection is established through mechanical contact between male and female connectors, eliminating the need for welding operations while maintaining connection reliability.
Solution Approach 2:
The patent divides the electrical connection system into separate modular components: functional cards with male connectors and rack receptacles with female connectors. These segmented components can be independently manufactured and assembled by simple insertion, eliminating the need for time-consuming welding of entire wire harnesses.
2Adaptability or versatility
If wire harnesses or flexible cables are used for electrical connections, then flexibility is provided, but the minimum length constraint of greater than 30 mm limits dimensional freedom
Solution Approach 1:
The patent segments the connection system into discrete male and female connector components that can be positioned independently. This eliminates the minimum length constraint of flexible cables, as the rigid connector elements can be placed at optimal positions without being limited by cable bend radius or minimum length requirements.
3Adaptability or versatility
If male contacts mounted to move along their longitudinal axis are used, then relative movement is allowed, but connection security is reduced in hostile environments with vibrations and accelerations
Solution Approach 1:
The patent incorporates dynamic elements through articulated connection members with ball joints that allow controlled relative movement between the functional card and rack while maintaining secure connection. The ball joints provide rotational freedom to accommodate misalignment and vibration, yet maintain positive mechanical engagement to prevent connection loss under acceleration.
4Adaptability or versatility
If articulated connection members with ball joints are used, then relative movement and alignment tolerance are accommodated, but the device complexity increases
Solution Approach 1:
The patent uses ball joints in articulated connection members to provide dynamic alignment compensation. The ball joints enable rotational movement that automatically accommodates misalignment between male and female connectors during insertion and operation, simplifying the assembly process while maintaining connection reliability without requiring complex adjustment mechanisms.
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 secure, flexible, and rapid assembly of functional cards in racks, maintaining reliable connections even in harsh environments, reducing assembly time and enhancing durability against vibrations and contaminants.
Implementation Method 1
each electrical connection element further comprises a rigid electrical connection member, one end of which is connected via a first articulation to the first contact part and the other end of which is connected via a second articulation to the second electrical contact part
Implementation Method 2
said connector comprises a block of elastic and insulating material which coats the electrical connection members, the block of elastic material is made of silicone
Data Source
Figure 1~3
Figure 4~7
Figure 8~12
AI summary
The invention relates to an electric connector that comprises a plurality of electric connection elements (7) including a first electric contact portion (13) and a second electric contact portion (15), respectively, the electric contact portion (13, 15) including a male connector (32) or a female connector. Each electric connection element (7) further includes a rigid electric linking member (17) having one end connected via a first hinge (19) to the first contact portion (13) while the other end is connected via a second hinge (21) to the second electric contact portion (15), the first electric contact portions (13) being supported in a first base (3) while the second electric contact portions (15) are supported in a second base (5). The invention further relates to a corresponding electric connection element and to an electric linking member, and to a method for assembling such a connector.