Modular Electrical Connector With Pull-Force Release Locking

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Solution Overview

Problem

Existing electrical connectors, such as RJ12 connectors, are not suitable for users like children due to their complexity in unlocking and releasing, and are prone to breakage, especially when used in modular construction elements and systems, where they may be subjected to pull forces.

Innovation Solution

A modular electrical connector system featuring a strain relief part and lock and release elements that securely hold conductors and allow easy disconnection by applying a predetermined force, ensuring reliable and intuitive connection and disconnection, even for children, by releasing the coupling when subjected to pull forces above a certain threshold.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If standard RJ12 connectors are used, then electrical connection is established, but the connector is difficult to separate and lock reliably

Engineering Contradiction:

Improveconnection reliabilityVSAvoidseparation ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The connector employs a dynamic locking mechanism with resilient arms that can transition between locked and unlocked states. The resilient arms are biased to engage with the counterpart connector, providing automatic locking upon insertion, while allowing easy release when force is applied during separation attempts.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The connector is divided into separate functional components including resilient arms, locking elements, and contact elements. This segmentation allows each component to perform its specific function independently - the resilient arms provide locking, the contact elements provide electrical connection, and the housing provides structural support.

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If rigid wires are used in connectors, then structural stability is improved, but the connector becomes prone to breakage under pull forces

Engineering Contradiction:

Improvestructural stabilityVSAvoidresistance to pull forces

Core Design Contradiction:

Stability of the object's compositionVSStrength

Solution Approach 1:

The connector incorporates flexible cable management elements and strain relief structures that can deform under pull forces without breaking. The housing includes flexible portions and strain relief features that absorb mechanical stress, protecting the rigid internal components from damage.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The connector design includes built-in strain relief features and cable management structures that are positioned in advance to absorb and distribute pull forces. These features cushion the impact of accidental pulls before they can reach the critical components, preventing breakage.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Volume of moving object

If small form factor connectors are used, then space is saved, but the locking mechanism becomes difficult to operate for children

Engineering Contradiction:

Improveconnector sizeVSAvoidlocking mechanism operability

Core Design Contradiction:

Volume of moving objectVSEase of operation

Solution Approach 1:

The connector employs a self-locking mechanism that automatically engages when the connectors are mated, eliminating the need for manual locking operations. The resilient arms automatically snap into place, providing secure connection without requiring users to perform complex locking actions, making it suitable for children and easy-to-use applications.

Inventive Principle:

Principle #25Self-service

4Ease of operation

If accidental pulling is not prevented, then connector separation is simple, but device damage may occur

Engineering Contradiction:

Improveconnector separabilityVSAvoiddevice damage from pull forces

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The connector incorporates preliminary protective measures through strain relief structures and cable management features that are built into the housing. These features counteract the harmful effects of accidental pulling forces before they can transmit to the connected devices, while still allowing intentional separation when needed.

Inventive Principle:

Principle #9Preliminary anti-action

Data Source

PatentUS11824307B2Electrical connector and connector elements for a modular construction element and/or system

Publication Date: 2023.11.21 LEGO AS

AI summary

The presentation invention relates to a first electrical connector element for a modular construction element and/or system, including a first connector part having a plurality of electrical contacts electrically connected to a plurality of electrical conductors. The first electrical connector is adapted to connect with a second electrical connector element, and includes a strain relief part to securely hold the plurality of electrical conductors thereby securing the plurality of electrical conductors to the first electrical connector element. The first electrical connector also includes a number of lock and release elements for engaging with the second electrical connector element when mechanically and electrically coupled together and releasing the coupling of the first and the second electrical connector elements when subjected to one or more pull forces above a predetermined release threshold.