Keyed Electric Connector Housing for Mismating Prevention
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Solution Overview
Problem
Existing electrical connectors lack efficient mechanisms to ensure correct mating between keyed female and male housings, leading to potential mismating and damage, and require additional color coding for identification.
Innovation Solution
The implementation of keying systems with rib and groove patterns on both housings, providing nine different keying options, including rod, inverted-T, and T shapes, to ensure correct mating and prevent mismating by requiring higher insertion forces for incorrect combinations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If keying systems with rib and groove patterns are implemented on both housings, then correct mating is ensured and mismating is prevented, but device complexity increases
Solution Approach 1:
The patent employs asymmetric rib and groove patterns on the housings where the male housing has ribs protruding outward and the female housing has corresponding grooves. This asymmetric design ensures that only correctly oriented housings can mate, as the ribs fit into the grooves only in the proper configuration, thereby preventing mismating while maintaining structural clarity
Solution Approach 2:
The keying system is segmented into multiple independent rib-groove pairs distributed around the housing circumference. Each rib on one housing corresponds to a groove on the mating housing, creating discrete engagement points that collectively ensure proper alignment and prevent incorrect mating orientations
2Adaptability or versatility
If multiple keying patterns (rod, inverted-T, T shapes) are used to provide nine different keying options, then adaptability increases, but manufacturing complexity increases
Solution Approach 1:
The patent designs the rib and groove structures to serve multiple functions: they provide mechanical keying for prevention of mismating, offer tactile feedback for user guidance, and create nine distinct keying pattern combinations (including rod, inverted-T, and T shapes). This multi-functionality allows a single structural element to address multiple requirements, reducing the need for separate identification systems
Solution Approach 2:
Different regions of the housing circumference feature different rib-groove pattern configurations (rod shape, inverted-T shape, T shape). Each local region is optimized with specific pattern types to create the nine different keying options, allowing the housing to provide varied keying characteristics at different locations while maintaining consistent manufacturing processes
3Reliability
If rib and groove keying patterns are implemented on both male and female housings, then mismating prevention is improved, but ease of operation decreases due to higher insertion forces required for incorrect combinations
Solution Approach 1:
The rib and groove keying patterns are designed to create preliminary resistance to incorrect mating attempts. When housings are attempted to be mated in wrong orientations, the ribs encounter the grooves in mismatched configurations, generating immediate mechanical resistance that prevents incorrect assembly. This preliminary anti-action occurs before full insertion, providing clear feedback that deters mismating
Solution Approach 2:
The keying system provides tactile feedback during the mating process. When housings are correctly aligned, the ribs smoothly engage with corresponding grooves requiring minimal insertion force. When misaligned, the ribs conflict with grooves creating increased resistance and tactile sensation, giving the operator immediate feedback about correct versus incorrect orientation without requiring visual inspection
Data Source
AI summary
A connector having a male housing and a female housing with keying systems is provided. The keying system on the male housing has a first keying pattern and a second keying pattern. The keying system on the female housing has a third keying pattern and a fourth keying pattern. The keying patterns can be ribs and grooves. A rib of the first keying pattern can be inserted to a groove of the third keying pattern to allow mating of the male housing and the female housing. A rib of the second keying pattern can be inserted to a groove of the fourth keying pattern to allow mating of the male housing and the female housing.