Electrical Plug Connector Play-Limiting Element
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Solution Overview
Problem
Electrical plug connectors face challenges in meeting varying demands for vibration resistance and electromagnetic compatibility (EMC) while maintaining cost-effectiveness, as existing solutions require shielding plates that increase complexity and cost when EMC requirements are low.
Innovation Solution
The design incorporates a play-limiting element on the connector housing that protrudes through an opening in the shielding plate, allowing for defined and minimized play between the plug connector and mating connector, independent of the shielding plate's presence, ensuring robustness and EMC performance across different applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a shielding plate is used to improve EMC performance, then electromagnetic compatibility is improved, but device complexity and cost increase
Solution Approach 1:
The connector system allows dynamic configuration where the shielding plate can be optionally installed or removed based on specific application requirements. The play-limiting element is designed to work effectively in both configurations, enabling the connector to adapt its shielding level to match the EMC demands of different applications.
Solution Approach 2:
The shielding function is segmented from the basic connector structure. The shielding plate is designed as a separate, optional component that can be added when needed, while the core play-limiting mechanism remains independent and functional without it. This segmentation allows selective application of shielding based on requirements.
2Object-affected harmful factors
If a shielding plate is installed to meet high EMC requirements, then electromagnetic shielding is improved, but manufacturing cost increases
Solution Approach 1:
The connector system allows dynamic configuration where the shielding plate can be optionally installed or removed based on specific application requirements. The play-limiting element is designed to work effectively in both configurations, enabling the connector to adapt its shielding level to match the EMC demands of different applications.
Solution Approach 2:
The system allows changing the shielding parameter (presence or absence of shielding plate) based on application-specific EMC requirements. The play-limiting element's functionality remains consistent across different shielding configurations, enabling cost-effective manufacturing by producing connectors without shielding plates for applications where EMC requirements are low.
3Ease of manufacture
If the shielding plate is omitted to reduce cost, then manufacturing cost decreases, but the outer contour and interface behavior of the connector housing are influenced
Solution Approach 1:
The play-limiting element acts as an intermediary component that maintains the connector's interface behavior and outer contour consistency regardless of whether the shielding plate is present. It ensures that the connector housing's external characteristics remain stable, providing reliable mechanical engagement in both shielded and unshielded configurations.
Solution Approach 2:
The play-limiting element is designed to provide universal functionality across both shielded and unshielded configurations. It ensures consistent mechanical performance and interface behavior whether the shielding plate is installed or removed, making the connector housing universally applicable to different applications without compromising its external characteristics.
4Reliability
If play between connector housing and mating connector is reduced to improve vibration resistance, then mechanical robustness is improved, but device complexity increases
Solution Approach 1:
The play-limiting element is designed to automatically limit play between the connector housing and mating connector through its own structural characteristics, without requiring additional active components or complex adjustment mechanisms. The element inherently provides the necessary mechanical constraint to ensure vibration resistance and reliable electrical contact.
Data Source
AI summary
An electrical plug connector. The electrical plug connector has: a connector housing for accommodating at least one electrical cable that extends along an axial direction; a shielding plate that completely encloses the connector housing in a circumferential direction around the axial direction. The connector housing has, on an external surface, a play-limiting element for limiting a degree of play in the state plugged together with the mating plug connector. The shielding plate has an opening, the play-limiting element protruding from the connector housing and extending through the opening of the shielding plate and/or the play-limiting element being fashioned as a connector housing opening in the connector housing and being adjacent to the opening.