Locking Electrical Contact Assembly With Staged Energization
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Solution Overview
Problem
Existing electrical connectors lack a mechanism to prevent immediate energization of contacts upon insertion, posing safety risks and requiring separate actions for connection and disconnection.
Innovation Solution
A staged switching mechanism in the electrical connector assembly that includes a first and second portion with biased electrical contacts, an actuator, and a button to control engagement of these contacts, allowing for controlled energization and disengagement through a series of movements and positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If electrical contacts are immediately energized upon insertion, then connection speed is improved, but safety risks increase due to unexpected energization
Solution Approach 1:
The connector performs preliminary mechanical engagement and alignment before electrical contact is made. The housing and contact arrangement ensure that physical connection is established first, then energization occurs only after the connector is fully engaged and locked, preventing unexpected energization during insertion
Solution Approach 2:
The connection process is segmented into distinct phases: mechanical insertion, alignment, locking engagement, and then electrical energization. This segmentation allows the system to complete the physical connection safely before activating electrical contacts, resolving the conflict between speed and safety
2Reliability
If a lock mechanism is added to secure connectors, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The locking mechanism is merged with the housing structure itself rather than being a separate component. The housing includes integrated features that provide both structural support and locking functionality, reducing overall device complexity while maintaining connection reliability
Solution Approach 2:
The connector design allows the housing and contact arrangement to automatically provide locking and securing functions during the connection process. The structure itself performs the locking action without requiring additional active components, simplifying the device while improving reliability
3Object-affected harmful factors
If electrical contacts are spaced apart in extended position, then safety during withdrawal is improved, but connection time increases due to additional movement required
Solution Approach 1:
The electrical contacts are designed to dynamically adjust their spacing based on connector position. In the extended position, contacts are spaced apart for safety during withdrawal. During connection, the contacts automatically move into engagement position, and the system provides rapid make/break capability to minimize connection time while maintaining safety
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 connection and disconnection by maintaining electrical contacts in a non-energized state during insertion and withdrawal, enhancing user safety.
Implementation Method 1
a support member (82) positioned between the first electrical contacts and the second electrical contacts and configured to elastically deform
Data Source
AI summary
An electrical connector assembly includes a first electrical contact device and a second electrical contact device. The first electrical contact device includes a plurality of conductors. The second electrical contact device includes a first portion, a second portion movable in a rotational and translational manner relative to the first portion, and an actuator movable between a first position and a second position. The first portion includes first electrical contacts, and the second portion includes electrical sockets. Each socket receives an associated conductor and includes a second electrical contact aligned with an associated first electrical contact. The second portion is biased away from the first portion. When the actuator is in the first position, the actuator inhibits translational movement of the second portion toward the first portion. When the actuator is in the second position, the second portion is movable toward the first portion to permit the second electrical contacts to engage the first electrical contacts.