Plug Connector Holding Frame with Elastic Flange Parts
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Solution Overview
Problem
Existing holding frames for plug connector modules are time-consuming to assemble, prone to module misalignment, and lack the mechanical robustness and heat resistance required for metal plug connector casings, especially when replacing individual modules, due to material limitations and design flaws.
Innovation Solution
A holding frame design featuring a base frame with flange parts that can elastically bend and deform to securely fix modules, using different materials for the base and flange parts to enhance flexibility and stability, with latching windows and guide portions for precise module alignment and secure fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If holding frames are made as integral injection-molded plastic parts, then manufacturing complexity is reduced and assembly is simplified, but mechanical robustness, heat resistance, and suitability for protective earthing are insufficient
Solution Approach 1:
The holding frame combines a metal base frame (providing mechanical robustness, heat resistance, and electrical conductivity for protective earthing) with plastic flange parts (providing insulation and module retention). This composite construction resolves the contradiction by integrating materials with complementary properties to achieve both ease of manufacture and high mechanical strength.
2Ease of manufacture
If holding frames are made as integral injection-molded plastic parts, then manufacturing is simplified, but heat resistance is insufficient for special applications
Solution Approach 1:
The metal base frame provides superior heat resistance compared to plastic, enabling the holding frame to withstand high temperatures in special applications such as those near blast furnaces. The plastic flange parts are only used where thermal exposure is not critical, thus maintaining manufacturing simplicity while solving the heat resistance problem.
3Reliability
If holding frames require protective earthing according to EN 61984 standard, then electrical safety is improved, but plastic holding frames are generically unsuitable
Solution Approach 1:
The metal base frame provides the electrical conductivity required for protective earthing according to EN 61984 standard, ensuring electrical safety. Simultaneously, the plastic flange parts provide electrical insulation where needed. This composite structure achieves both electrical safety and material versatility.
4Strength
If flange parts are attached to base frame with attachment studs and recesses, then connection is secured, but deformation during module insertion may cause offset and reduced fixing reliability
Solution Approach 1:
The flange parts are designed as resilient, elastically deformable thin-walled structures that can flex during module insertion and return to their original position. This flexibility allows the flange parts to accommodate insertion forces without causing permanent offset, maintaining both connection strength and fixing reliability.
Solution Approach 2:
The flange parts transition from a static rigid connection to a dynamic resilient connection, allowing elastic deformation during module insertion. This dynamic behavior enables the connection to absorb insertion forces and maintain reliable module fixation without permanent misalignment.
5Ease of manufacture
If holding frames are made of plastic, then manufacturing by injection molding is simplified, but the heat resistance is not sufficient for special applications
Solution Approach 1:
The holding frame is segmented into two functional parts: a metal base frame for structural support and heat resistance, and plastic flange parts for module retention and insulation. This segmentation allows each part to be optimized for its specific function, with the metal base providing heat resistance and the plastic flanges providing ease of manufacture through injection molding.
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
The design significantly improves assembly efficiency, ensures secure module fixation, and provides the necessary mechanical robustness and heat resistance for use in metal plug connector casings, reducing the risk of module detachment and material fatigue.
Implementation Method 1
the flange parts are designed to undergo elastic bending and deformation between an insertion state which allows the module to be inserted into the holding frame in the insertion direction, and a holding state in which an inserted module is fixed in place
Implementation Method 2
each flange part has at least one latching window, in the region extending beyond the edge of the base frame, as a latching element for receiving a latching lug of the module
Data Source
AI summary
A holding frame comprising a base frame and at least two flange parts which are attached to the base frame opposite each other is proposed, in which each flange part extends outside the base frame along an outer face of the base frame in an insertion direction, around a lower edge of the base frame, inside the base frame along an inner face of the base frame in the opposite direction to the insertion direction and beyond an edge of the base frame in the opposite direction to the insertion direction, wherein each flange part has at least one latching window, in the region extending beyond the edge of the base frame, as a latching element for receiving a latching lug of the module to fix the module in the holding frame.