Compact Electrical Plug with Outer Signal Contacts
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Solution Overview
Problem
Existing electrical plug connections for connecting a battery pack to an electrical working device are large and cumbersome due to the need for separate lines for power and signal transmission, which impedes efficient use and requires a significant overall size.
Innovation Solution
The design shifts signal-transmitting contacts to the outer contour of the plug body, forming a mechanical latching connection with a spring tongue mating contact on the socket, allowing for a smaller plug size and secure mechanical locking while maintaining reliable electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate lines for power and signal transmission are provided, then reliable electrical contact is achieved, but the overall size of the plug connection increases
Solution Approach 1:
The patent combines power transmission and signal transmission functions within a single integrated plug connection structure. Multiple electrical lines (both power and signal) are arranged together in the plug body, with power contacts and signal contacts co-located in the same connector housing, thereby achieving reliable electrical contact while maintaining compact dimensions.
Solution Approach 2:
The patent utilizes three-dimensional spatial arrangement within the plug body to accommodate multiple electrical lines. By arranging power contacts and signal contacts in different spatial positions and orientations within the same plug volume, the design achieves comprehensive electrical connectivity without increasing the overall plug size, effectively utilizing vertical and radial dimensions.
2Object-affected harmful factors
If signal-transmitting contacts are placed inside the plug body, then protection against electromagnetic interference is achieved, but the plug diameter increases
Solution Approach 1:
The patent nests signal-transmitting contacts within the interior cavity of the plug body, surrounded by the conductive housing structure. The signal contacts are positioned inside the plug body and enclosed by the housing walls, which act as a shield against electromagnetic interference, while the nested arrangement prevents increase in external plug dimensions.
Solution Approach 2:
The patent applies different functional qualities to different regions of the plug body. The housing material in regions surrounding signal contacts possesses electromagnetic shielding properties, while the signal contacts themselves are positioned in specific locations where they can transmit signals effectively without protruding outward, thus protecting against interference without increasing diameter.
3Reliability
If a mechanical latching connection is formed, then secure mechanical locking is achieved, but the device complexity increases
Solution Approach 1:
The patent merges the electrical contact function and mechanical latching function into a single integrated contact element. The external contact serves dual purposes: transmitting electrical signals and providing mechanical locking through its engagement with the mating contact, thereby achieving secure mechanical locking without adding separate locking mechanisms or increasing structural complexity.
Solution Approach 2:
The external contact is designed as a multi-functional element that simultaneously performs electrical signal transmission and mechanical locking operations. This universal component interacts with the mating contact to provide both electrical connectivity and secure mechanical retention, eliminating the need for separate dedicated locking parts and reducing overall device complexity.
4Ease of operation
If the plug is designed for easy insertion with haptic feedback, then ease of operation is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent incorporates a ramp structure on the external contact that generates haptic feedback during insertion. As the plug is inserted, the ramp engages with the mating contact and creates a tactile sensation (click or resistance change) that signals proper engagement, improving ease of operation without requiring complex electronic sensors or feedback mechanisms.
Solution Approach 2:
The ramp is pre-formed as an integral part of the external contact during manufacturing. The geometric shape of the ramp is designed beforehand to automatically provide insertion guidance and haptic feedback when engaged, eliminating the need for post-assembly adjustments or additional components, thus maintaining manufacturing simplicity while enhancing user experience.
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 configuration enables a compact, reliable, and mechanically secure electrical connection that facilitates easy insertion and secure locking, providing haptic feedback and ensuring interference-free signal transmission with a reduced plug size.
Implementation Method 1
the signal-transmitting mating contact being designed as a spring tongue
Data Source
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AI summary
The invention relates to an electrical connector for the detachable electrical connection of a power source to an electrical device (3). The connector (1) comprises at least one first electrical conductor (17, 18) for transmitting electrical power and at least one second electrical conductor (19, 20) for transmitting signals. The connector (1) consists of a plug (4) with a plug body (5) and one or more first plug contacts (6, 7) and a socket (8) with first contact sockets (9, 10), wherein the plug contacts (6, 7) of the first electrical conductor (17, 18) are arranged within the plug body (5). According to the invention, the plug contact of the second electrical conductor (19, 20) is designed as an outer contact (11, 12) in the region of an outer contour of the plug body (5), wherein the outer contact (11, 12) of the plug body (5) is associated with a mating contact (13, 14) of the socket (8).The outer contact (11, 12) and the counter contact (13, 14) form a latching connection (15).