Plug Connector Ingress Barrier Structure for IP20 Finger Safety

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Solution Overview

Problem

Traditional plug connectors do not meet the IP20 'Finger Safe' rating requirements, which could lead to safety issues when pin contacts are energized even when disconnected from their mating socket.

Innovation Solution

An IP20-rated electrical plug connector design that includes a plug insert with a pin contact, a contact tip insulator, and a removable ingress protection frame with ingress barriers, which together ensure that the plug connector is finger-safe by narrowing the ingress opening to less than 12 mm.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the ingress opening is made wide for service access, then ease of operation is improved, but finger safety is compromised

Engineering Contradiction:

Improveservice accessVSAvoidfinger safety

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The connector is divided into functional zones: the ingress opening area is segmented from the contact area by the contact tip insulator and ingress protection frame. This segmentation allows the opening to remain accessible for service while the barriers prevent finger access to energized contacts, resolving the contradiction between ease of operation and finger safety.

Inventive Principle:

Principle #1Segmentation

2Ease of repair

If the ingress protection frame is made removable for service, then ease of repair is improved, but device complexity increases

Engineering Contradiction:

ImproveserviceabilityVSAvoidconnector structure

Core Design Contradiction:

Ease of repairVSDevice complexity

Solution Approach 1:

The ingress protection frame transitions from a static protective barrier to a dynamic, removable component. It can be in a fixed state during operation to provide IP20 protection, and removed during service to allow access to contacts. This dynamic capability enables easy repair while maintaining safety during normal use, accepting increased structural complexity as a trade-off.

Inventive Principle:

Principle #15Dynamics

3Object-affected harmful factors

If the contact tip insulator is added to narrow the ingress opening, then finger safety is improved, but device complexity increases

Engineering Contradiction:

Improvefinger safetyVSAvoidconnector structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The contact tip insulator serves as an intermediary element between the contact tip and the external environment. It narrows the ingress opening to prevent finger access to energized contacts while allowing the connector to maintain its basic structure. This intermediary component provides the necessary IP20 protection with minimal additional complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS20250047045A1Connector With Removable Ingress Protection Element

Publication Date: 2025.02.06 HARTING ELECTRIC STIFTUNG & CO KG

AI summary

An electrical plug connector (100) may include a plug insert (130), and a pin contact (150) arranged within the plug insert (130). The electrical plug connector is IP20 “Finger Safe.” Finger safety is achieved by a contact tip insulator (160) that may be fastened to a front end of the pin contact (150) and a removable ingress protection frame (170) comprising ingress barriers (176) arranged between a side wall (132) of the plug insert (130) and the pin contact (150).