Plug-In Connector Geometry for 360° Misalignment Prevention
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Solution Overview
Problem
Existing connector arrangements often face issues with easy and correct alignment during mating, leading to potential reverse polarity and misalignment, especially in multi-pole configurations, which can result in a cumbersome twisting process to achieve proper insertion.
Innovation Solution
The use of two springs of different lengths, integrated with a bevel design in the mating connector, ensures guided insertion by forcing each spring into its corresponding groove, preventing misalignment and facilitating correct positioning during the mating process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the connector and mating connector are designed with standard mating faces, then the contact partners can be connected, but the connector may not be plugged into the mating connector in the correct position, leading to reversed polarity or misalignment
Solution Approach 1:
The connector features two opposing springs of different lengths (first spring longer than second spring) that engage with corresponding grooves in the mating connector. This asymmetric design creates a unique geometric relationship that allows the connector to be inserted only in the correct rotational position, preventing reversed polarity while maintaining a simple push-in operation without requiring twisting or multiple attempts
Solution Approach 2:
The bevel in the plug-in area of the mating connector performs preliminary alignment action before the springs engage with the grooves. The beveled surface guides the connector into the correct angular position as it approaches the mating connector, ensuring that the longer spring aligns with its groove first, which then forces the shorter spring into its groove, establishing correct positioning before final contact partner engagement
2Ease of operation
If the connector is designed to allow easy insertion without alignment features, then the plug-in process is simple, but the connector and mating connector cannot achieve correct alignment immediately, requiring twisting and several attempts
Solution Approach 1:
The asymmetric spring lengths create a directional insertion path where the longer spring engages its groove before the shorter spring, allowing the connector to be pushed straight in without twisting while ensuring correct rotational alignment. The geometric constraint of the asymmetric springs within the mating connector's grooves provides immediate positive alignment upon insertion
Solution Approach 2:
The beveled plug-in surface performs the preliminary alignment function, guiding the connector into the correct angular position before the springs engage. This preliminary action eliminates the need for twisting or multiple attempts, as the bevel pre-positions the connector correctly as it approaches the mating connector
Data Source
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AI summary
The invention relates to a plug-in connector arrangement (1) comprising a plug-in connector (2) with a contact support (6) and a mating connector (3) with a contact support (7) that can be plugged together with the plug-in connector (2), the mating connector (3) having a chamfered portion (10) in the plug-in region, which corresponds to the geometry of the plug-in connector (2) in such a way that, during the plug-in process, the plug-in connector (2) is inserted into a pre-defined position in the mating connector (3), the plug-in connector (2) comprising two opposing springs (8) extending axially in the plug-in direction and the mating connector (3) comprising two opposing grooves (9), or vice versa, each spring (8) corresponding to the related groove (9). The invention is characterized in that the two springs (8) have different lengths.