Locking Housing Interface for Electrical Contacts
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Solution Overview
Problem
Existing electrical connectors with friction-based interfaces suffer from inconsistent performance, wear, and degradation due to metal-on-metal contact during connect-disconnect cycles, requiring different forces for insertion and removal, and are not suitable for applications under load or stress.
Innovation Solution
A locking housing with a low friction interface using a ramp interface and incline hooks to delay electrical contact and provide a secure connection, reducing wear and requiring user intervention for disconnection, while maintaining durability and consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If friction-based interfaces are used to retain electrical contacts, then connection retention is achieved, but wear and degradation occur over connect-disconnect cycles
Solution Approach 1:
A non-conductive ramp interface is introduced as an intermediary element between the electrical contacts. This ramp surface provides a low-friction path that delays direct metal-to-metal contact until the connectors are substantially inserted, thereby reducing wear during connection while still achieving secure retention through the locking mechanism
Solution Approach 2:
The ramp interface performs a preliminary function by guiding and delaying the contact between electrical connectors. The low-friction ramp surface prepares the connection path before the actual electrical contact occurs, reducing the impact and wear of the final engagement
2Reliability
If metal-on-metal contact is used for electrical connection, then electrical conductivity is achieved, but surface degradation occurs during connect-disconnect cycles
Solution Approach 1:
The non-conductive ramp interface serves as a mediator that delays the metal-on-metal contact. By providing a low-friction guiding surface, it reduces the severity and frequency of direct contact between electrical surfaces, thereby minimizing arc-induced degradation while maintaining reliable electrical conductivity when connected
3Device complexity
If the same force is used for insertion and removal of electrical contacts, then simplicity is maintained, but inconsistent performance occurs due to installation variations
Solution Approach 1:
The connection and disconnection operations are segmented into distinct phases with different force requirements. The ramp interface facilitates easy insertion with minimal force, while the locking mechanism provides secure retention. For removal, a separate unlocking phase is introduced that allows controlled disengagement without requiring excessive force, thereby achieving consistent performance despite installation variations
4Reliability
If locking mechanisms are added to prevent accidental disconnect, then connection security is improved, but ease of operation is reduced
Solution Approach 1:
The locking mechanism is designed with dynamic characteristics that allow it to engage automatically during insertion, providing secure retention during normal use. For disconnection, the mechanism can be deliberately actuated to release, transforming from a locked state to an unlocked state. This dynamic behavior maintains security during operation while allowing intentional disconnection when needed
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
The solution reduces frictional wear, increases the longevity of electrical contacts, and ensures consistent and secure connections, enhancing ease of use and safety by minimizing the force required for connection and disconnection.
Implementation Method 1
A locking housing with a low friction interface using a ramp interface and incline hooks to delay electrical contact and provide a secure connection, reducing wear
Data Source
AI summary
A locking coupling for electrical connections that provides a low-friction interface that delays contact between conductive contacts and retains electrical and mechanical connection with a locking mechanism. A terminal plug embodiment and a coupling embodiment are disclosed, a button release mechanism and a locking recessed mechanism are disclosed.