High Temperature Plug Connector with Latching Hooks for Knock Sensors
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Solution Overview
Problem
Connectors with high-temperature-resistant cable sheaths pose challenges in achieving longitudinal watertightness and strain relief due to the inability of overmolding compounds to bond with these materials, and existing assembly methods are complex and prone to errors.
Innovation Solution
The use of a contact carrier with a latching tab for primary locking of contact partners and latching hooks that create a form-fitting connection with the cable sheath for watertightness and strain relief, along with a separate housing seal inserted into a circumferential groove for enhanced sealing, simplifies assembly and ensures proper locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an overmolding process is used to form the outer housing, then longitudinal watertightness and strain relief are achieved, but the method cannot be applied to high-temperature-resistant cable sheaths because the overmolding compound cannot bond with these materials
Solution Approach 1:
A separate housing seal inserted into a circumferential groove acts as an intermediary element between the outer housing and the cable sheath. This seal provides the bonding interface for longitudinal watertightness without requiring the overmolding compound to directly bond with the high-temperature-resistant cable sheath material.
Solution Approach 2:
The sealing function is segmented into a separate housing seal component rather than being integrated into the overmolding process. This allows the seal to be independently designed and inserted into the circumferential groove, decoupling the bonding requirement from the cable sheath material.
2Reliability
If contact partners are equipped with resilient spring clips for latching, then secure fixing in the contact carrier is achieved, but the shaping and production of contact partners becomes complex
Solution Approach 1:
The resilient spring clip latching mechanism is extracted from the contact partner design. Instead of equipping each contact partner with a spring clip, the latching function is provided by a separate latching element that engages with the contact carrier, simplifying contact partner manufacturing.
3Reliability
If care is taken to ensure proper latching of spring clips during assembly, then secure connection is achieved, but the assembly process becomes complex and error-prone
Solution Approach 1:
The latching mechanism is designed to be self-latching during assembly. The resilient latching element automatically engages with the contact carrier when the contact partner is inserted, eliminating the need for manual intervention to ensure proper latching and reducing assembly complexity.
4Reliability
If a separate housing seal is inserted into a circumferential groove, then longitudinal watertightness is achieved with high-temperature-resistant materials, but an additional assembly step is required
Solution Approach 1:
The housing seal is pre-inserted into the circumferential groove of the outer housing before final assembly with the cable. This preliminary action ensures the seal is in place and properly positioned, making the subsequent assembly process simpler and more reliable.
Data Source
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AI summary
The invention relates to a method for mounting a plug connecter (1), comprising a contact carrier (30), which is designed to receive at least one contact partner (22) that is arranged on an electrical conductor (21) of a cable (20), wherein the contact carrier (30) is inserted in an outer housing (40). The invention is characterized in that the contact carrier (30) is provided with a latching lug (31) for fixing the at least one contact partner (22) in the contact carrier (30), and at least one latching hook (32) arranged at the end thereof and acting on the cable (20). Both the latching lug (31) and the at least one latching hook (32) are moved from an initial position into a functional position whenever the contact carrier (30) is inserted into the outer housing (40).