Misalignment Tolerant Electrical Connector with Conical Alignment

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Solution Overview

Problem

Existing environmentally sealed electrical connectors often interfere with the proper orientation and coupling of their halves, especially in applications like solar modules where one or both halves are not hand-accessible, leading to difficulties in alignment and insertion.

Innovation Solution

The design incorporates alignment features such as conical surfaces and a ratcheting locking mechanism to allow for misalignment tolerance between the plug and socket assemblies, ensuring a reliable and environmentally sealed electrical connection, even in blind settings, by using a plug assembly with an elastomeric tip and a socket assembly with a positioning ring for radial and angular alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a flexible sealing member is used to provide environmental sealing, then sealing reliability is improved, but alignment and coupling difficulty increases

Engineering Contradiction:

Improvesealing reliabilityVSAvoidalignment and coupling

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The connector incorporates pre-formed alignment features including a conical alignment surface on the plug and a corresponding conical recess on the socket, along with a positioning ramp. These alignment features are prepared in advance to guide the mating process, allowing the connector to self-align during coupling even when misalignment is present, thereby resolving the contradiction between sealing reliability and alignment ease

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The connector is divided into distinct functional segments: an alignment segment with conical surfaces and positioning ramp, a sealing segment with the flexible member, and a coupling segment. This segmentation allows each feature to perform its specific function independently, with the alignment segment preparing the mating halves before the sealing segment engages, thus improving both sealing reliability and coupling ease

Inventive Principle:

Principle #1Segmentation

2Strength

If the connector halves are made rigid for structural stability, then structural strength is improved, but tolerance to misalignment decreases

Engineering Contradiction:

Improvestructural strengthVSAvoidmisalignment tolerance

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The connector employs a positioning ramp that allows dynamic adjustment during the mating process. The ramp enables the socket to move radially and angularly relative to the plug, accommodating misalignment dynamically as the connectors come together. This dynamic capability allows rigid structural components to maintain strength while the system as a whole tolerates misalignment through controlled movement during coupling

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If alignment features are added to improve coupling accuracy, then alignment precision is improved, but device complexity increases

Engineering Contradiction:

Improvealignment precisionVSAvoidconnector structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The alignment feature utilizes a conical geometry with a predetermined angle, where the curved surface naturally guides misaligned connectors into proper alignment through geometric constraint. This curved alignment surface provides precise alignment functionality while maintaining a relatively simple single-piece molded structure, avoiding the need for multiple complex adjustment mechanisms

Inventive Principle:

Principle #14Spheroidality (Curvature)

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

This solution enables reliable and efficient electrical connections in situations with significant misalignment, particularly beneficial for solar modules, reducing the need for extra cabling and improving aesthetics by allowing close spacing of photovoltaic modules while ensuring optimal energy capture and minimizing vertical space.

Implementation Method 1

The elastomeric tip of the plug assembly is provided to effect a compression fit in the socket barrel

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

The plug assembly and the socket assembly include alignment features to align the conductive receptacle and the second conductor during coupling of the socket assembly and the plug assembly

Methodology Applied

Scientific EffectGeometric alignment: Geometry

Implementation Method 3

The plug assembly and the socket assembly include a locking feature to secure the socket assembly and plug assembly in a coupled position

Methodology Applied

Scientific EffectMechanical locking: Mechanical Fastener

Data Source

PatentUS7530830B1Misalignment tolerant connector

Publication Date: 2009.05.12 UNIRAC INC

AI summary

An electrical connector having a plug assembly and a socket assembly is described. The plug assembly includes a plug body and an outer barrel with an inner conductive receptacle electrically coupled to a first conductor in the plug body. The socket assembly includes a socket body movably held within an outer housing by a positioning ring, the socket body having a socket barrel with a second conductor fixed therein to be received in the conductive receptacle of the plug assembly. The plug assembly and the socket assembly include alignment features to align the conductive receptacle and the second conductor during coupling of the socket assembly and the plug assembly.