Intermediate Connector Locking Structure for Oblique Decoupling Prevention
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Solution Overview
Problem
Existing intermediate electrical connectors face challenges in preventing inadvertent decoupling, especially when held in an oblique orientation due to insufficient engagement force between insulating materials, leading to potential disconnection under their own weight.
Innovation Solution
The introduction of metallic locking fittings with cantilevered resilient locking pieces and engaging portions that securely engage with lockable portions on the counterpart connector, ensuring a strong locking mechanism even in oblique orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If engaging portions are formed from electrically insulating material to prevent interference with plugging and unplugging, then ease of operation is improved, but locking strength deteriorates causing inadvertent decoupling under weight
Solution Approach 1:
The connector is divided into two functional parts: engaging portions made of electrically insulating material for easy plugging/unplugging, and locking portions made of metal for strong locking. This segmentation allows each part to optimize its material properties for its specific function.
Solution Approach 2:
Different parts of the connector have different material qualities: the engaging portions use insulating material for operational ease, while the locking portions use metal for strength. This local differentiation of material properties resolves the contradiction between ease of operation and locking strength.
2Strength
If intermediate electrical connector dimensions in up-down direction are increased to provide sufficient engagement force, then locking strength is improved, but weight increases causing decoupling under gravity
Solution Approach 1:
The material parameter is changed from electrically insulating material to metal for the locking portions, dramatically increasing strength and engagement force without increasing dimensions or weight. This material parameter change allows achieving sufficient locking strength in a compact, lightweight design.
3Reliability
If locking portions are added to prevent inadvertent decoupling, then reliability is improved, but device complexity increases
Solution Approach 1:
The locking portions are integrated into the same component structure as the engaging portions, forming a unified connector assembly. This merging approach provides reliable locking functionality without adding separate complex mechanisms, thus improving reliability while minimizing increases in device complexity.
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
This solution enhances the locking strength between the intermediate electrical connector and the counterpart connector, effectively preventing decoupling even when the connectors are held in oblique positions, ensuring reliable connection and disconnection.
Implementation Method 1
locking pieces that are obtained by cutting out and raising a portion of the plate-shaped sections so as to extend in the direction of disengagement from the first counterpart connect body
Data Source
AI summary
An intermediate electrical connector 1 which, upon connection of a first counterpart connect body 2 and a second counterpart connect body each from different sides in a manner permitting plugging and unplugging, mediates between the two counterpart connect bodies, the intermediate electrical connector 1 comprising terminals that are enabled to contact, respectively, the first counterpart connect body 2 and the second counterpart connect body, and a housing that directly or indirectly secures the terminals in place, wherein the connector has locking fittings 100 supported by the housing of the intermediate electrical connector 1, and the locking fittings 100 have locking portions 104A enabled to engage lockable portions 151 provided in the first counterpart connect body 2 in the direction of disengagement when the intermediate electrical connector 1 and said first counterpart connect body 2 are connected.