Plug Connector Housing That Blocks Actuation During Mating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing plug connections lack secure and efficient mechanisms to prevent unintentional release of electrical conductors, require additional elements for conductive connections, and often occupy excessive space, complicating installation and increasing the risk of mismating and unauthorized access.
Innovation Solution
The plug connection design incorporates insulating walls that block actuation of the actuating element in the assembled state, ensuring the electrical conductor is clamped or released only when the plug connector is pulled out of the socket, with features like trough-shaped insulating walls, mismating protection, and secure latching mechanisms to prevent unauthorized removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the actuating element is made accessible in the plugged-in state for easy conductor release, then ease of operation is improved, but unintentional release and unauthorized access increase
Solution Approach 1:
The insulating walls are designed to preemptively block the actuating element in the plugged-in state, preventing any accidental or unauthorized actuation before it can occur. The blocking action is built into the structural design, creating a preliminary barrier that must be overcome before conductor release can happen.
Solution Approach 2:
The plug connector is designed with the actuating element positioned and blocked in advance during the plugging operation. The insulating walls are configured to automatically engage and block the actuating element as soon as the plug connector is inserted into the plug socket, preparing the system to prevent unintentional release before the plugged-in state is fully established.
2Adaptability or versatility
If cross jumpers are added to connect clamping points electrically conductively, then connectivity is improved, but device complexity increases
Solution Approach 1:
The cross jumper element is completely removed from the system. Instead of adding a separate conductive connector between clamping points, the busbar itself is designed to provide the necessary electrical connectivity, extracting the unnecessary intermediate element and simplifying the overall device structure.
Solution Approach 2:
The busbar is designed to serve multiple functions simultaneously: it provides electrical connectivity between clamping points and serves as a structural component of the contact insert. This multi-functionality eliminates the need for separate cross jumpers, reducing device complexity while maintaining electrical adaptability.
3Reliability
If the plug connection design includes comprehensive protection features and latching mechanisms, then reliability is improved, but device complexity increases
Solution Approach 1:
Multiple protection functions are merged into the insulating walls structure. The insulating walls simultaneously provide electrical insulation, mechanical blocking of the actuating element, structural support for the plug connector, and guidance features. This consolidation achieves comprehensive connection security without proportionally increasing device complexity.
Solution Approach 2:
The insulating walls are designed as multi-functional elements that perform several protective and structural roles at once: blocking the actuating element, providing electrical insulation, supporting the plug connector, and preventing mismating. This multi-functionality achieves high reliability while minimizing the number of separate components needed.
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 design ensures secure, compact, and efficient electrical connections with reduced installation space, preventing unintentional release and mismating, while allowing easy assembly and enhanced vibration resistance, suitable for casting applications.
Implementation Method 1
the contact insert having a busbar and a clamping spring, the busbar and the clamping spring forming a first clamping point for the electrical conductor
Implementation Method 2
an actuation of the actuating element is blocked by at least one of the insulating walls in an assembled state of the plug connector and the plug socket
Data Source
AI summary
A plug connection including a plug connector and a plug socket for electrically conductively connecting a circuit board. The plug connector has an insulating housing with a conductor insertion opening for guiding an electrical conductor into the insulating housing. A contact insert is received in the insulating housing, which has a busbar and a clamping spring. The insulating housing having a contact pin receiving opening for guiding a contact pin into the insulating housing. The busbar having a second clamping point for the contact pin. An actuating element is configured to open and/or close the first clamping point. An actuation of the actuating element is blocked by at least one of the insulating walls in an assembled state of the plug connector and the plug socket.