Plug Connector Insulating Part Cover Mechanism

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing plug connectors risk short circuits due to contact between inner conductors and outer conductors, particularly when individual wires of the inner conductors are not properly clamped, leading to potential electrical shorts.

Innovation Solution

An insulating part with a cover that can move from an open to a closed position, preventing contact between inner conductors and the outer conductor, featuring a base body with bores and a connected cover that pivots to cover the openings, ensuring electrical insulation during assembly and operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If individual wires of the inner conductor are not fully clamped between the lugs, then the crimp connection may be insufficient, but this can lead to short circuits if the loose wires contact the outer conductor

Engineering Contradiction:

Improvecrimp connection simplicityVSAvoidelectrical insulation reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The cover acts as an intermediary protective element between the inner conductor (specifically the crimped wires) and the outer conductor. It provides an additional layer of insulation that prevents short circuits even when the crimp connection is insufficient, without interfering with the crimping process itself.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The cover is positioned beforehand to cover the opening of the insulating part, creating a protective barrier before the inner conductor is inserted. This pre-positioned protection ensures that even if wires are not fully clamped, they cannot contact the outer conductor and cause a short circuit.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Ease of operation

If the insulating part has an open bore for inserting the inner conductor, then assembly is simplified, but the inner conductor may contact the outer conductor causing short circuits

Engineering Contradiction:

Improveassembly easeVSAvoidshort circuit risk

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The cover is designed to be movable, transitioning from an open position during assembly to a closed protective position during operation. This dynamic behavior allows the system to maintain ease of assembly while preventing short circuits in the final assembled state.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The insulating part is segmented into a base body with the bore and a separate movable cover. This segmentation allows the bore to remain open for easy insertion while the cover can be positioned to close the opening and prevent contact with the outer conductor.

Inventive Principle:

Principle #1Segmentation

3Reliability

If the cover is added to prevent short circuits, then electrical insulation is improved, but the device complexity increases

Engineering Contradiction:

Improveshort circuit preventionVSAvoidinsulating part structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cover is integrated with the insulating part as a single component, merging the insulation function with the protective cover function. This reduces the number of separate parts and simplifies manufacturing while maintaining the short circuit prevention capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cover is designed to be self-positioning and self-retaining, using its own elastic properties to snap into place and remain closed during operation. This eliminates the need for additional locking mechanisms or complex assembly procedures, maintaining simplicity despite the added protective function.

Inventive Principle:

Principle #25Self-service

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 solution effectively prevents short circuits by ensuring that all inner conductors are insulated from the outer conductor, even when individual wires are not fully clamped, enhancing the reliability and safety of the connector.

Implementation Method 1

The insulating part, which is made of an electrically insulating material, ensures that the inner conductors are permanently positioned at a distance from an outer conductor that completely surrounds the insulating part

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentEP2915218B1Plug connector with insulating part

Publication Date: 2016.11.09 ROSENBERGER HOCHFREQUENZTECHNIK GMBH & CO KG

Figure 1~2
Figure 3~4
Figure 5~6

AI summary

The present invention relates to an insulating part for a plug connector with a base with a bore for receiving an internal conductor of the plug connector and an aperture which opens in radial direction into the bore, via which the internal conductor can be inserted into the bore, wherein a covering connected to the main body is provided, which in a first position releases the aperture and in a second position covers the aperture.