Plug-in Connector Fixing Element Vibration Resistance
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Solution Overview
Problem
Connectors used in the motor vehicle sector face issues with breakage due to vibrations and contact corrosion in the crimping area, leading to increased resistance and potential electrical failures.
Innovation Solution
A plug connector design featuring a fixing element that engages in an opposite recess in the connector base element, providing additional fixation points and a prestressed locking mechanism to secure the contact element, combined with a conical secondary locking recess and a T-shaped fixing element, which enhances stability and prevents corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If only primary and secondary locking mechanisms are used to secure the contact element, then the locking function is achieved, but the contact element remains vulnerable to vibration-induced breakage and corrosion in the crimping area
Solution Approach 1:
The fixing mechanism is divided into two distinct components: a fixing element integrated into the contact element and a separate fixing component in the connector base element. This segmentation allows each part to be optimized independently while working together to provide comprehensive vibration resistance without excessive overall complexity.
Solution Approach 2:
The fixing element extends in a direction transverse to the insertion direction, creating a new spatial dimension for fixation. This transverse extension allows the fixing element to engage with the fixing component in a direction perpendicular to the main insertion axis, providing additional stabilization against vibration forces from multiple directions.
2Reliability
If the fixing element is arranged close to the secondary locking element, then the structure is compact, but the crimping area lacks sufficient fixation and remains prone to vibration damage
Solution Approach 1:
The fixing element is positioned at the end of the crimping area and extends transversely to the insertion direction, utilizing a spatial dimension perpendicular to the main axis. This allows maximum separation along the insertion direction while maintaining compact transverse dimensions, providing crimping area fixation without excessive overall length.
3Reliability
If the contact element is rigidly fixed to prevent all movement, then vibration resistance is improved, but the insertion process becomes difficult and contact element wear increases
Solution Approach 1:
The fixing element is designed to engage with the fixing component in a controlled sequence during insertion. The conical geometry of the fixing component allows the fixing element to move freely during insertion, then progressively locks into position as insertion completes, providing vibration resistance only when needed while maintaining ease of insertion.
Solution Approach 2:
The conical fixing component is pre-positioned in the connector base element before the contact element is inserted. This preliminary arrangement guides the fixing element into proper alignment during insertion, ensuring smooth engagement without requiring forceful insertion or causing excessive wear, while still providing firm fixation once inserted.
Data Source
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AI summary
Disclosed is a plug-in connector (100) comprising at least one contact element (200) arranged in a base element (110) of the plug-in connector, and a crimp connection. At least one secondary locking recess (205, 206) is arranged in the contact element (200), extending transverse to the plug-in direction (R). A locking stud (305, 306) of a secondary locking element (300) engages with the secondary locking recess (205, 206) in the locked position of the secondary locking element (300). The disclosed plug-in connector (100) is characterized by a fixing element (215) which is arranged at the end of a crimp region and which engages with a mating recess (115) in the base element (110) of the plug-in connector.