Removable Ingress Protection Frame for IP20 Plug Connectors
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Solution Overview
Problem
Traditional plug connectors do not meet IP20 'Finger-Safe' requirements, as they are not designed to prevent access to energized pin contacts when disconnected from their mating socket.
Innovation Solution
An IP20-rated electrical plug connector is designed with a plug insert that securely holds a pin contact, a contact tip insulator, and a removable ingress protection frame. The ingress protection frame includes ingress barriers that narrow the ingress opening to less than 12 mm when installed, making the connector finger-safe.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the ingress opening is made wide for service access, then ease of operation is improved, but finger safety is compromised
Solution Approach 1:
The ingress protection frame is divided into separate retention arms that can be independently removed, allowing service access while maintaining finger safety when installed. The retention arms with chamfered protrusions can be removed to access pin contacts for service, but when present, they create the IP20-rated barrier.
Solution Approach 2:
The ingress protection frame is designed to be removable rather than fixed, allowing dynamic adjustment between service mode (frame removed, wide access) and operational mode (frame installed, finger-safe). This enables the same structure to serve dual purposes at different times.
2Ease of repair
If the ingress protection frame is made removable for service, then ease of repair is improved, but structural complexity increases
Solution Approach 1:
The ingress protection frame is segmented into multiple retention arms that can be independently removed, simplifying the removal process for service while maintaining the overall structural integrity when assembled. This segmentation makes the complex structure easier to manipulate during maintenance.
Solution Approach 2:
Instead of making the entire ingress protection frame a single complex piece, the design inverts the approach by using multiple simple retention arms that clip onto the base plate. The complexity is distributed and simplified through this inverted assembly approach.
3Ease of manufacture
If the retention arms are designed with chamfered protrusions for clip-connection, then ease of manufacture is improved, but device complexity increases
Solution Approach 1:
The retention arms are segmented components with standardized chamfered protrusions that can be manufactured independently and assembled through simple clip-connection. This segmentation allows each part to be manufactured using standard processes while the assembly creates the functional complexity.
Solution Approach 2:
The chamfered protrusions on the retention arms are designed to self-align and snap into the window openings of the plug insert through clip-connection. This self-service feature eliminates the need for complex fastening mechanisms or precision alignment procedures during assembly.
Data Source
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AI summary
An electrical plug connector may include a plug insert (130), and a pin contact (150) arranged within the plug insert (130). The electrical plug connector may be IP20 "Finger-Safe." Finger-safety is achieved by a contact tip insulator (160) that may be fastened to a front end of the pin contact (150) and a removable ingress protection frame (170) comprising ingress barriers (176) arranged between a side wall (132) of the plug insert (130) and the pin contact (150).