High-Voltage Connector Locking Mechanism for Vibration Resistance
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Solution Overview
Problem
Existing electrical connectors, particularly in the automotive industry, face challenges with sealing and vibration resistance, especially under adverse environmental conditions, which can lead to unintentional disconnection and interference with electrical signals.
Innovation Solution
The electrical connector design includes a connector housing with a locking element and an actuating element that moves between positions, featuring a locking mechanism with locking lugs and stops to ensure secure engagement and resistance to vibration, using a direct positive locking connection to maintain the connector in a locked position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional locking mechanism is used, then the connector can be assembled, but it lacks sufficient sealing and vibration resistance under adverse environmental conditions
Solution Approach 1:
The locking mechanism is divided into separate functional elements: locking lugs on the actuating element, corresponding stops on the connector housing, and sealing elements positioned independently. This segmentation allows each component to be optimized for its specific function while maintaining overall reliability without excessive complexity.
Solution Approach 2:
The locking lugs and stops are pre-positioned on the actuating element and connector housing respectively, so that when the actuating element is inserted, the locking engagement occurs automatically without requiring additional locking actions. The sealing elements are pre-installed to ensure immediate sealing upon connection.
2Reliability
If a simple connector design is used, then manufacturing is easier, but the connector cannot prevent unintentional disconnection during vehicle operation
Solution Approach 1:
The actuating element serves dual functions: it acts as the moving component for connection establishment and simultaneously as the locking element through its integrated locking lugs. This self-service approach ensures secure connection without requiring separate complex locking mechanisms, maintaining ease of manufacture while improving connection security.
3Reliability
If the actuating element is blocked in the locked position, then the connection is secure, but the unlocking process becomes less optimal under adverse environmental conditions
Solution Approach 1:
Instead of designing the locking mechanism to actively engage and hold the actuating element, the design inverts the approach: the locking lugs on the actuating element passively engage with the stops on the housing when the actuating element is in its locked position. The actuating element's own movement and positioning create the locking condition, making the locked state stable and the unlocking process simple by reversing the actuating element's movement.
Data Source
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AI summary
The invention relates to an electrical connector (2), comprising a connector housing (5), a securing element (41) and an actuating element (4) which can be moved between a home position (P0) and a locking position (P1) and which is designed to lock the electrical connector (2) with a corresponding electrical counterpart connector (3). The connector housing (5) has a locking guide (40) for guiding the securing element (41) between an initial position (S0) and a securing position (S1). In the securing position (S1), the securing element (41) is engaged with the actuating element (4) in such a manner that the actuating element (4) is locked in the locking position (P1). The securing element (41) has at least one latching tab (42) and the locking guide (40) has at least one first stop (44) for the at least one latching tab (42) for blocking the securing element (41) initially in the initial position (S0) in the direction towards the securing position (S1), wherein the actuating element (4) has at least one releasing body (45) which is designed to penetrate into a recess (46) in the locking guide (40) and to displace the at least one latching tab (42) of the securing element (41) relative to the at least one first stop (44) of the locking guide (40), to release the displacement path of the securing element (41), proceeding from the initial position (S0) into the securing position (S1).