Electrical Plug Connector Cap Locking Mechanism
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Solution Overview
Problem
Existing electrical connectors with snap-on caps are prone to loosening or destruction due to leverage forces from rigid cable harnesses, particularly in environments with vibrational movements, leading to unstable electrical connections.
Innovation Solution
The introduction of positively connected slide surfaces with receiving grooves that lock with molded locking hooks on the cap, eliminating the need for a latching threshold and providing a stable connection that withstands greater forces, including those from cable harnesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a latching connection is used to attach the cap to the connector housing, then the cap can be easily attached and detached, but the connection becomes unstable under leverage forces from the cable harness
Solution Approach 1:
The connection system is divided into two distinct parts: latching elements for easy attachment/detachment operation, and locking hooks for stable force resistance. The locking hooks are integrated into the slide surfaces while the latching elements remain on the cap, creating a segmented functional architecture that addresses both ease of operation and connection stability independently
Solution Approach 2:
The locking mechanism transitions from a two-dimensional latching interface to a three-dimensional interlocking structure. The locking hooks extend from the slide surfaces into recesses within the connector housing, creating depth-based mechanical interlocking that resists leverage forces in multiple directions, not just the simple snap-fit direction
2Adaptability or versatility
If the cable harness is mechanically connected to the cap for strain relief, then cable positioning is improved, but significant leverage forces can loosen or destroy the latching connection
Solution Approach 1:
The locking hooks act as an intermediary mechanical element between the cap and the connector housing. When the cable harness is mounted to the cap, the locking hooks transmit and distribute the resulting leverage forces through the slide surfaces into the connector housing structure, preventing these forces from directly attacking the latching connection
3Device complexity
If ordinary locking hooks are used to connect the cap to the connector housing, then the structure is simple, but the connection cannot withstand greater forces from the cable harness
Solution Approach 1:
The locking hooks are merged with the slide surfaces as an integrated structure. The slide surfaces serve dual functions: guiding the insertion movement and housing the locking hooks that provide enhanced force resistance. This merging eliminates the need for separate locking components while achieving superior mechanical strength
Data Source
Figure 1~2
Figure 3a~5b
AI summary
The invention relates to an electrical plug connector which comprises a first (1) and a second plug connector housing, slider surfaces (6) being insertable into the first plug connector housing (1) at a right angle to the direction of insertion of the plug connector, and slanted guide grooves (7) being molded onto the slider surfaces (6) and cams being molded onto the second plug connector housing, or cams being molded onto the slider surfaces (6) and slanted guide grooves (7) being molded onto the second plug connector housing. When the slider surfaces (6) are inserted into the first plug connector housing (1), the cams are guided along the guide grooves (7) and effect a relative displacement of the plug connector housings towards each other. The side of the first plug connector housing (1) opposite the connecting side is closed by a lockable cap (4), the slider surfaces (6) inserted into the first plug connector housing (1) being form-locked with the cap (4).