Plug Connector Assembly for 360° Mating Without Polarity Reversal
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Solution Overview
Problem
Connector assemblies often face issues with incorrect positioning during mating, leading to potential polarity reversals and undesired rotation, which complicates the mating process, especially in multi-pole configurations where the latching principle is not applicable.
Innovation Solution
The use of two springs with different lengths in the main connector, which engage sequentially with corresponding slots in the mating connector, ensures correct positioning and prevents obstruction or skewing during insertion, allowing for oblique mating and maintaining the advantages of the spring and slot design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the main connector is inserted into the mating connector without positioning measures, then the mating process is simple, but the main connector may not be inserted in the correct position leading to polarity reversals
Solution Approach 1:
The chamfer on the mating connector is pre-formed to guide the main connector into the correct position during insertion. This preliminary geometric feature ensures that as the main connector approaches the mating connector, the chamfer automatically aligns it correctly before contact partners engage, preventing polarity reversals without requiring complex active positioning mechanisms.
Solution Approach 2:
The chamfer creates an asymmetric geometry at the insertion interface, where one side of the mating connector has a sloped surface while the other remains flat or differently configured. This asymmetry ensures that the main connector can only be inserted in the correct orientation, as inserting it incorrectly would cause mechanical interference or inability to engage the chamfer properly.
2Manufacturing precision
If latching connector assemblies are used to ensure correct positioning, then positioning accuracy is improved, but the design becomes more complex and is not applicable to multi-pole configurations
Solution Approach 1:
The invention extracts the essential positioning function from the complex latching mechanism and implements it through the simple chamfer geometry. By removing the need for latching components, hooks, or complex interlocking features, the solution achieves correct positioning through the chamfer's guiding action alone, thereby reducing device complexity while maintaining positioning accuracy.
Solution Approach 2:
The chamfer serves multiple functions simultaneously: it guides the main connector into correct alignment, prevents incorrect orientation, and works with any number of contact partners arranged in various configurations. This universal approach eliminates the need for configuration-specific latching mechanisms, making the solution applicable to both two-pole and multi-pole connector assemblies regardless of contact partner arrangement.
3Manufacturing precision
If rotation of the main connector is required to locate the correct position, then positioning accuracy can be achieved, but the mating process requires multiple attempts and more time
Solution Approach 1:
The chamfer is pre-configured on the mating connector to perform the alignment action during the insertion process itself. As the main connector approaches and makes contact with the chamfered surface, the geometry automatically guides it into the correct rotational position and linear alignment, eliminating the need for preliminary rotation attempts by the operator.
Solution Approach 2:
The chamfer introduces a curved or sloped surface geometry that guides the main connector smoothly into the correct position during insertion. This curved guiding surface allows the connector to self-align through the insertion motion itself, converting what would require separate rotation adjustments into a single smooth insertion action.
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 facilitates easy and positionally correct mating by ensuring the main connector is aligned correctly with the mating connector, preventing rotation and ensuring proper contact alignment, even in confined spaces, thus simplifying the mating process.
Implementation Method 1
The two springs have different lengths. Fundamentally, the plug-in principle, which is known from EP 2 822 106 A1 and is based upon the spring and slot design described therein, is maintained, in order to permit the maintenance of the resulting advantageous functions thereof, specifically in an oblique mating process.
Data Source
AI summary
A connector assembly (1) comprising a main connector (2) with a contact support (6), and a mating connector (3) that can be mated with the main connector (2), having a contact support (7), wherein the mating connector (3), in the plug-in region, is formed with a chamfer (10) that corresponds to the shape of the main connector (2) such that, during the mating process, the main connector (2) is inserted into the mating connector (3) in a predefined position, wherein the main connector (2) comprises two axially extending springs (8), arranged in opposition in the plug-in direction, and the mating connector (3) comprises two opposing slots (9), or vice versa, wherein a spring (8) corresponds to its respective slot (9), characterized in that the two springs (8) have different lengths.