Internally Switched Receptacle with Plug-Latching Safety Interlock
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Solution Overview
Problem
Existing pin-and-sleeve electrical connectors lack effective mechanisms to ensure safe energization and disengagement of receptacle contacts, risking accidental exposure to live electrical components unless a mating plug is properly inserted.
Innovation Solution
A receptacle design with a releasable plug latch, spring-loaded catch, and interlock mechanism that keeps sleeve and inner contacts disengaged until the plug is fully inserted, featuring a modular clocking design and pass-through ground conductor for enhanced safety and versatility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the receptacle uses internally switched contacts that remain open when no plug is present, then safety is improved by preventing accidental exposure to live electrical components, but the device complexity increases due to the need for additional switching mechanisms
Solution Approach 1:
The patent combines the plug latch mechanism and the contact switching mechanism into a single integrated interlock system. The follower that actuates the switch contacts is directly linked to the plug insertion motion, and the catch that latches the plug is mechanically connected to the same follower assembly. This merging of functions reduces overall device complexity while maintaining the safety benefits of internally switched contacts.
Solution Approach 2:
The interlock mechanism is designed to automatically switch the contacts and engage the latch without requiring separate control systems. The plug insertion motion itself drives the follower, which simultaneously actuates the switch contacts and triggers the latch engagement through mechanical linkage. This self-service approach eliminates the need for additional motors, sensors, or control circuits that would increase device complexity.
2Reliability
If the receptacle includes a plug latch with catch mechanism to prevent accidental separation, then reliability is improved by ensuring secure connection, but the ease of operation deteriorates due to the additional steps required for plug insertion and removal
Solution Approach 1:
The catch mechanism is pre-positioned and spring-loaded to automatically engage with the plug's indexing tab as soon as the plug is fully inserted. The follower is pre-configured to trigger the latch engagement sequence before the user needs to manually secure the connection. This preliminary action ensures secure connection without requiring the user to perform additional manual steps.
Solution Approach 2:
The latch engagement and contact switching actions occur rapidly in sequence during the final stage of plug insertion. The mechanical linkage transmits the plug insertion motion directly and quickly to both the follower (for contact switching) and the catch (for latch engagement). This rushing through of the securing actions minimizes the time and effort required for the user to complete the connection.
3Loss of information
If the receptacle provides visual status indication through LED circuit, then information feedback is improved for user awareness, but the device complexity increases due to additional electronic components
Solution Approach 1:
The LED status indication is driven by the existing internal switch contacts that are already required for the safety function. The LED circuit uses the same electrical pathways and switching mechanisms that control the power delivery, acting as an intermediary that provides visual feedback without requiring separate sensing or control circuits. This approach provides information feedback while minimizing additional device complexity.
4Adaptability or versatility
If the receptacle uses a modular clocking design with peripheral knockouts for variable angular positioning, then adaptability is improved for various configurations, but the manufacturing precision requirements increase
Solution Approach 1:
The receptacle housing is segmented with standardized peripheral knockouts arranged at specific angular intervals. The inner contact support can be positioned at different angular locations by selecting different knockout positions during assembly. This segmentation provides adaptability for various configurations while using simple, repeatable manufacturing features that do not require high precision.
Solution Approach 2:
The angular positioning of the inner contact support is achieved by changing the positional parameter of the selected knockout during assembly, rather than requiring precision adjustment mechanisms. The standardized knockout locations provide discrete angular positions that satisfy various configuration needs while maintaining simple manufacturing requirements for the housing itself.
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 safe and reliable energization only when the plug is fully engaged, providing a visual status indication and ensuring the primary circuit is grounded throughout insertion and withdrawal, while allowing for various configurations and easy maintenance.
Implementation Method 1
A spring-loaded catch is provided in the receptacle and is movable between a catch position and a released position
Implementation Method 2
The interlock includes at least one follower in the plug-receiving cavity displaceable by a plug during its axial insertion into the housing
Data Source
AI summary
An internally switched female receptacle or connector for use with IEC 60309-2 configuration plugs and the like. Various plug-latching and plug-actuated safety interlock arrangements coordinate strictly axial plug movement relative to the receptacle with the closing and opening of sleeve contacts and terminal pressure contacts. A continuous ground feature ensures grounding of the primary electrical circuit throughout plug insertion and withdrawal. An optional low-current lighting control circuit powers an LED status indicator. A modular clocking design enables variable angular positioning of the terminals during manufacture.