Plug Connector Chamber Isolation for Moisture Short-Circuit Prevention
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Solution Overview
Problem
High-current electrical connector arrangements face risks of short circuits due to loose contact elements and penetration of electrically conductive fluids, despite existing sealing measures, which can lead to damage and safety issues, especially at high currents and voltages.
Innovation Solution
A plug connector design featuring a housing with separate contact chambers and a contact locking element, where a wall or groove between chambers redirects water away from forming a short-circuit path, and a sensor can detect moisture to interrupt the current flow before a short circuit occurs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If sealing elements are provided to prevent water ingress, then protection against liquid penetration is improved, but short circuits can still occur due to seal aging or damage over time
Solution Approach 1:
The connector housing is divided into separate contact chambers that are physically isolated from each other by walls. This segmentation ensures that even if water penetrates the outer seal, it cannot form a continuous conductive path between adjacent contact chambers, preventing short circuits between contact elements.
Solution Approach 2:
The patent introduces a spatial dimension of isolation by creating vertically stacked contact chambers separated by insulating walls. This three-dimensional arrangement prevents lateral water flow between contacts, adding a geometric barrier dimension to the protection strategy beyond just sealing.
2Ease of operation
If contact elements are made loose for easy insertion, then ease of operation is improved, but contact elements may become unintentionally released causing short circuits
Solution Approach 1:
A contact locking element is provided that automatically engages with the contact elements upon insertion to prevent their unintentional release. The locking element counteracts the loosening force before it can cause a problem, maintaining secure contact while allowing easy insertion through the locking mechanism's automatic engagement.
Solution Approach 2:
The contact locking element acts as an intermediary component between the contact elements and the housing. It mediates between the need for easy insertion and secure retention by providing a mechanical locking interface that holds contact elements in place without interfering with the insertion process.
3Reliability
If contact chambers are separated into distinct chambers, then short circuit prevention is improved, but device complexity increases due to additional walls and structures
Solution Approach 1:
The housing structure serves multiple functions: it provides mechanical support, contains contact elements, prevents short circuits through chamber separation, and guides the locking element. By making the housing multi-functional, the patent reduces the need for separate components, thereby limiting the increase in device complexity.
Solution Approach 2:
The patent combines the functions of short circuit prevention and contact element retention into a unified housing design with integrated locking mechanisms. The walls separating contact chambers also serve as mounting surfaces for the locking element, merging structural and functional requirements into a single integrated solution.
Data Source
Figure 1a
Figure 1b~1c
Figure 2
AI summary
The invention relates to a plug connector (1) for pushing onto or into a mating plug connector (30) having at least two mating contact elements (31) along a plug-in direction (S). The plug connector (1) has a housing (2) with a first plane (3) that faces the plug-in direction (S). The housing (2) has at least two contact chambers (4), each of which having an opening (5) in the first plane (3). At least two of the contact chambers (4) are formed separated from one another in the housing (2). Between at least two adjacent contact chambers (4), a wall (7) is arranged that projects from the first plane (3) viewed counter to the plug-in direction (S). Alternatively or additionally, at least one groove is arranged in the first plane (3) between at least two adjacent contact chambers (4).