Plug Connector Assembly Decoupling Sealing and Contact Forces
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Solution Overview
Problem
Existing electrical connector arrangements require significant joining forces due to the coupling of contact and sealing forces, leading to bulky mechanisms and high costs for zero-force connectors, which are complex and expensive.
Innovation Solution
The connector design decouples sealing and contact forces by fixing the contact carrier insert to the first connector housing, allowing axial compression of the seal only after plug-in contact elements are assembled, using a force-amplifying means like a rotary lever to compress the seal radially against housing walls, thus achieving a moisture-tight seal with reduced assembly effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact forces and sealing forces are applied simultaneously during connector assembly, then secure electrical connection and moisture protection are achieved, but the required joining force becomes excessively large requiring bulky force-amplifying mechanisms
Solution Approach 1:
The patent segments the assembly process into two distinct phases: first establishing electrical contact between plug and socket elements, then separately compressing the seal. This separation allows each function to be optimized independently, avoiding the need to apply both forces simultaneously which would require excessive total force.
Solution Approach 2:
The seal is pre-compressed during the connector housing assembly before the final plug-in connection is made. This preliminary sealing action ensures moisture protection is established early, allowing the electrical contact elements to be connected without requiring additional force for seal compression.
2Force
If zero-force connectors with clamping sleeve mechanisms are used to reduce assembly force, then contact forces are generated only in the final assembly phase, but the connector design becomes complex and expensive
Solution Approach 1:
The patent extracts the seal compression function from the electrical contact mechanism. Instead of using complex zero-force connectors with clamping sleeves that integrate both functions, the seal compression is handled separately through the surrounding housing and force-amplifying means, allowing simpler electrical contact elements to be used.
Solution Approach 2:
The seal itself acts as an intermediary element that transfers the radial compression force from the axial movement of the surrounding housing. This mediator mechanism simplifies the force transmission path compared to direct clamping sleeve mechanisms, reducing structural complexity while maintaining the zero-force connector benefit.
3Ease of manufacture
If the contact carrier insert is fixed to the first connector housing, then the seal compression is decoupled from contact element assembly, but the surrounding housing must be designed to provide force amplification
Solution Approach 1:
The patent merges the seal compression function with the surrounding housing structure itself. The surrounding housing incorporates guide pins and guide tracks that provide the force-amplifying mechanism, eliminating the need for separate force-amplification components while integrating the compression function into the housing design.
Solution Approach 2:
The patent converts the seal compression from a direct axial force application to a radial compression through dimensional transformation. The force-amplifying mechanism uses axial movement of the surrounding housing to generate radial compression of the seal through the guide pin and track geometry, utilizing a different dimensional approach to achieve the same sealing function.
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
This design simplifies and cost-reduces the connector arrangement by allowing easy compression of the seal with minimal effort, decoupling the force application from contact element assembly, and providing a reliable seal without the need for zero-force connectors, suitable for connectors with fewer plug-in elements.
Implementation Method 1
the seal between the connector housings is axially compressed and thereby radially expanded and is pressed against at least one inner housing wall of the surrounding housing and at least one outer housing wall of the contact carrier insert
Data Source
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AI summary
The invention describes an electrical plug connector assembly, consisting of a first plug connector housing (1), in which first plug contact elements are arranged, and a second plug connector housing (2), in which second plug contact elements are arranged, wherein the second plug connector housing consists of an enclosure (5) and a contact carrier insert (6), which can be moved in relation to one another by means of a force-amplifying means (7), wherein the contact carrier insert (6) has recesses for accommodating the second plug contact elements, wherein the first and second plug connector housings each have at least one housing wall, which housing walls have sections parallel to one another when the plug connector housings are interconnected, between which sections a seal (11) is arranged, which abuts at least one housing wall of each of the first and second plug connector housings when the plug connector housings are interconnected, wherein the second plug contact elements are arranged immovably in relation to the contact carrier insert (6), wherein the contact carrier insert (6) can be locked to the first plug connector housing (1), and wherein the enclosure (5) can be moved in relation to the contact carrier insert (6) by means of a rotational or translational actuation of the force-amplifying means (7).