Plug Connector Blocking Mechanism for Secure Position Assurance
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Solution Overview
Problem
Existing electrical plug devices lack a mechanism to ensure complete and secure connection, particularly in high-voltage applications, and often compromise the sealing integrity due to the presence of position assurance elements that project into the connector housing.
Innovation Solution
A blocking mechanism is integrated into the electrical plug device, allowing the position assurance element to be displaced to a securing position only when the mating housing is fully plugged, using a release element that is resiliently deflectable and a locking mechanism to prevent premature fixation, ensuring a sealed connection without projections into the interior space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a position assurance element is used to secure the connection aid in a holding position, then the connection is secured against unintentional release, but the position assurance element projects into the connector housing and compromises the sealing integrity
Solution Approach 1:
The position assurance element is moved from an internal position (projecting into the connector housing) to an external position (on the outer side of the connector housing). This dimensional change allows the element to perform its securing function while maintaining the sealing integrity of the connector housing interior.
Solution Approach 2:
The position assurance element is extracted from the interior space of the connector housing and repositioned on the outer side. This extraction eliminates the interference with the sealed connection while preserving the element's function of securing the connection aid in the holding position.
2Ease of operation
If the position assurance element is made movable to allow displacement to securing position, then the connection aid can be fixated, but the element may be moved prematurely before complete plugging
Solution Approach 1:
A blocking mechanism is implemented that prevents the position assurance element from being moved to the securing position until the complete plugging condition is met. The blocking mechanism applies a counter-action (blocking) that is removed only when the mating housing is fully plugged, ensuring proper connection sequence.
Solution Approach 2:
The blocking mechanism is designed to be released automatically when the mating housing is fully plugged, which preliminarily prepares the system by removing the block and enabling the position assurance element to be moved to the securing position only after complete connection is achieved.
3Reliability
If a blocking mechanism with a release element is added to control the position assurance element, then premature fixation is prevented, but the device complexity increases
Solution Approach 1:
The blocking mechanism is integrated with the position assurance element itself, combining the blocking function and the position assurance function into a single integrated component. This merging reduces the number of separate parts and simplifies the overall structure while maintaining the required control functionality.
Solution Approach 2:
The position assurance element is designed to serve multiple functions: it acts as both the element that secures the connection aid in the holding position and as part of the blocking mechanism that controls the sequence of operations. This multi-functionality reduces the need for additional dedicated components.
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 enhances safety and sealing by preventing incomplete connections and maintaining a sealed interior space, while allowing for a secure and complete plug engagement.
Implementation Method 1
the at least one release element is resiliently deflectable away from the connector housing
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to an electrical plug device (1) for an electrical plug connection and an assembly (3) comprising an electrical plug device (1) according to the invention. In order to increase the safety of a plug connection, an electrical plug device (1) is provided according to the invention with a connector housing (11) for receiving at least one electrical contact element, wherein the connector housing (11) is configured to be plugged together in a plugging motion with a mating housing (19) of a mating connector (5) configured to be complementary to the connector housing (11), wherein the electrical plug device (1) comprises at least one connection aid (13) that is formed to be engageable with the mating housing (19) and that forms a drive device (21) for the plugging motion between the connector housing (11) and the mating housing (19), wherein the connection aid (13) is held to be movable at the connector housing (11) from a plugging position (25) to a holding position (27), wherein the connector housing (11) in the plugging position (25) is connectable to the mating housing (19) and the mating housing (19) in the holding position (27) is held at the connector housing (11), wherein the electrical plug device (1) comprises at least one position assurance element (15) which is held at an outer side (29) of the connector housing (11) to be displaceable from an open position (31) to a securing position (33), wherein the connection aid (13) in the open position (31) of the position assurance element (15) is movable from the plugging position (25) to the holding position (27) and in the securing position (33) of the position assurance element (15) is fixated in the holding position (27) at the connector housing (11), and wherein a blocking mechanism (35) is provided with which the position assurance element (15) is blocked in the open position (31) and which comprise at least one release element (37) with which the blocking mechanism (35), in a state (39) of the connector housing (39) and the mating housing (19) being plugged together, is released.