Interlocking Connector Guide Channels Prevent Disengagement
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Solution Overview
Problem
Existing connectors require additional hardware for assembly, which increases costs and weight, and often have components that can inadvertently disengage, especially when handled frequently.
Innovation Solution
A connector design that uses guide channels and projections to interlock components without additional fasteners, providing a secure locking mechanism that prevents accidental disengagement, with optional features for strain relief, electrical shielding, and environmental protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional hardware (fasteners, springs, retention pins) is used to couple connector components, then the connection strength and reliability are improved, but the device complexity, cost, and weight increase
Solution Approach 1:
The patent integrates the fastening function directly into the connector housing structure through molded-in features such as clips, tabs, and interference-fit elements. These features are formed as integral parts of the housing during the molding process, eliminating the need for separate fasteners, springs, and retention pins. This merging of functions reduces the number of discrete hardware components while maintaining connection reliability.
Solution Approach 2:
The connector housing incorporates self-latching mechanisms and self-retaining features that automatically engage and lock components in place during assembly. The molded-in clips and tabs are designed to deform and lock into corresponding recesses without requiring additional fastening operations or separate retention hardware. The structure serves its own fastening needs through its inherent geometric design.
2Ease of manufacture
If snap-fit (interference fit) is used to couple components, then the assembly process is simplified and hardware is reduced, but the connection may inadvertently disengage under environmental exposure or frequent handling
Solution Approach 1:
The patent employs flexible latching elements and resilient tabs that can dynamically adapt to assembly variations and environmental stresses. These features are designed with appropriate flexibility to accommodate thermal expansion, vibration, and repeated mating cycles while maintaining secure engagement. The dynamic characteristics allow the connection to absorb stresses without disengaging.
Solution Approach 2:
The connector components utilize composite material structures combining rigid and flexible regions within the same molded part. The housing incorporates both stiff sections for structural support and flexible sections for latching and retention functions. This composite approach within the molded material allows the snap-fit features to provide both ease of assembly and reliable retention under various operating conditions.
3Adaptability or versatility
If multiple separate components are used to provide strain relief, shielding, and environmental protection, then the functionality is comprehensive, but the number of parts and assembly steps increases
Solution Approach 1:
The patent designs the connector housing to perform multiple functions through integrated features. The same housing structure provides mechanical support, strain relief for attached cables, electromagnetic shielding through conductive materials or coatings, and environmental protection through sealed constructions. This multi-functional design eliminates the need for separate accessories for each protective function.
Solution Approach 2:
The patent combines strain relief features, shielding elements, and environmental seals into the main housing structure through integral molding or co-molding techniques. Cable clamps and strain relief ribs are formed as part of the housing, conductive shielding layers are integrated into the housing walls, and sealing features are molded into the housing geometry. This merging reduces the total component count while maintaining comprehensive functionality.
Data Source
AI summary
A connector that includes a main body having ends and sides with a passage extending between the ends. The passage is configured to receive at least one of conductors and cables and the main body includes a guide channel that extends from at least one end and a guide channel that extends from at least one side into the main body. The guide channels join each other at an intersection. The connector also includes a first accessory that has a projection inserted into one of the guide channels and a second accessory that has a projection inserted into another of the guide channels. The projections engage each other at the intersection to secure the first and second accessories to the main body. A connector having a clamp sub-assembly secured to one end is also provided.