Insulator Cap Alignment for Connector Contact Reliability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional connector systems face challenges in achieving precise alignment and secure connection of male and female contact elements, leading to potential misalignment, plastic deformation, and costly repairs due to the elastic nature of female contact elements.
Innovation Solution
An insulator body with an integrated insulator cap that provides a guiding function, aligning male contact elements during plugging and preventing misalignment, while maintaining electrical properties through a non-conductive material and secure attachment methods like ultrasonic welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If female contact elements have resilient sections to enable elastic deformation for contact formation, then contact reliability is improved, but the diameter of female contact elements must be reduced, which worsens the cross-sectional area available for control by male contact elements
Solution Approach 1:
The insulator body is segmented into a main body and an insulator cap, with the insulator cap providing additional structural support and guiding surfaces that enable larger-diameter female contact elements to maintain both elastic functionality and adequate cross-sectional area for precise control by male contact elements
2Device complexity
If conventional insulator bodies are used without additional guiding structures, then device complexity is reduced, but alignment precision between male and female contact elements deteriorates, leading to misalignment and potential plastic deformation
Solution Approach 1:
The insulator cap is designed with guiding surfaces that preliminarily align and guide the male contact elements during the plugging process, ensuring precise positioning before the elastic contact elements engage, thereby preventing misalignment and plastic deformation
Solution Approach 2:
The insulator cap acts as an intermediary structure between the main body and the external environment, providing guiding surfaces that mediate the alignment process and ensure precise positioning of contact elements during connection
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
Ensures precise alignment and secure connection of cable sections, preventing misalignment and plastic deformation, thus enhancing the reliability and durability of electrical contacts without affecting electrical properties.
Implementation Method 1
an insulator body (10) for a round plug connector, having a plurality of recesses (26) which extend through the insulator body (10) and in which female contact elements (34) are arranged, characterised in that the insulator body (10) has an insulator cap (12) arranged on a main body (14)
Implementation Method 2
secure attachment methods like ultrasonic welding
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to an insulator body (10) for a connector, in particular a circular connector, comprising: a main body (14) with a plurality of main body recesses (26), wherein each main body recess (14) penetrates the main body (14) in a longitudinal direction of the main body (14), and an insulator cap (12), wherein the insulator cap (12) is arranged on an end face of the main body (14), wherein the insulator cap (12) has a plurality of insulator cap recesses (28), wherein, in the connected state of the insulator cap (12) with the main body (14), the plurality of insulator cap recesses (28) are aligned with the plurality of main body recesses (26), and wherein each insulator cap recess (28) is conically tapered.