Plug Connection With Nested Adapter Housing For Harsh Environments
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Solution Overview
Problem
Existing plug connections are limited in their ability to handle harsh environments and mechanical/chemical loads, and require increased installation space for connector parts like fiber optic technology, failing to provide a universal and easy-to-use solution with or without additional adapter housings.
Innovation Solution
A plug connection design featuring rectangular plug and socket housings with multiple rows of electrical contacts, a frame-like contact carrier with elastically expandable guide sleeves, and a latching mechanism for secure assembly, along with adapter housings that provide a high degree of protection, allowing for easy and secure assembly of contacts in harsh environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a known design for achieving higher protection class is used, then environmental protection is improved, but installation space increases and mechanical/chemical load resistance is not optimally met
Solution Approach 1:
The plug part and socket part are nested within the adapter housing, with the connector housing containing the contact carrier and contacts. This nested arrangement allows the protection class to be improved by the adapter housing while maintaining compact dimensions, as each component is efficiently space-utilizing within the hierarchical structure.
Solution Approach 2:
The adapter housing serves multiple functions: it provides the higher protection class (IP65/IP67), houses the plug and socket parts, provides mechanical strength for harsh environments, and enables universal applicability for different connector types. This multi-functionality resolves the contradiction by achieving environmental protection without proportionally increasing installation space.
2Adaptability or versatility
If the connector is designed for electrical signals only, then signal transmission is optimized, but adaptability to other connector parts like fiber optic technology is reduced
Solution Approach 1:
The adapter housing is designed as a universal mounting structure that can accommodate different types of connector parts including electrical plugs, fiber optic connectors (SC simplex inserts), and other communication connectors. The standardized housing design with appropriate sealing and mounting features enables this versatility without requiring fundamentally different designs for each connector type.
Solution Approach 2:
The connector system is segmented into modular components: the adapter housing (提供保护 class), the connector housing, and the contact carrier. This segmentation allows the adapter housing to serve as a universal platform that can interface with different connector types, while each connector type maintains its specialized contact carrier design, thus achieving adaptability without excessive overall complexity.
3Quantity of substance
If multiple rows of electrical contacts are provided in rectangular housings, then contact density is improved, but manufacturing complexity increases
Solution Approach 1:
Multiple rows of electrical contacts are merged into a single integrated contact carrier structure with multiple guide sleeves. This combining approach allows multiple contacts to be manufactured and assembled as one unit, increasing contact density while managing manufacturing complexity through standardization and modular assembly of the contact carrier within the connector housing.
4Ease of operation
If the contact carrier is made movable for easy assembly, then ease of assembly is improved, but structural stability during operation may be compromised
Solution Approach 1:
The contact carrier is designed with dynamic characteristics - it can move during assembly to facilitate insertion and latching, but transitions to a stable fixed position once assembled. The guide sleeves provide controlled movement paths, and the latching mechanism ensures the carrier achieves and maintains a stable operational position, thus resolving the contradiction between ease of assembly and structural stability.
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
The invention relates to a plug connection (1) comprising a. a plug part (6) and a socket part (7), said parts having corresponding interconnecting mating faces with a plug housing (9) and a socket housing (10), said mating faces encompassing a plurality of metal, electrically conducting female and male contacts (11, 12) b. and adapter housings (4, 5) into which the plug and socket parts (6, 7) can be inserted, said housings preferably capable of being plugged together and preferably locked together – in particular latched or screwed together -, wherein c. the plug housing (9) and/or the socket housing (10) comprise a contact support (17, 117) at which the contacts (11, 12) can be pre-mounted, said support and contacts being movable from a pre-mounting position to a final mounting position at a contact support (21, 121) after pre-mounting of the contacts (11, 12).