Plug-in Connector Resilient Side Wall for High Retention
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Solution Overview
Problem
Existing plug-in connectors lack sufficient pull-out force, leading to unintentional extraction of contact elements, and require high mounting forces, which can reduce service life and increase production costs.
Innovation Solution
A plug-in connector design featuring a contact chamber with an inelastic locating hook and resilient side walls, along with recesses and tapered portions, enhances the extraction force while allowing for a low-force mounting process, suitable for high-current and multipole connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional locking elements are used, then the contact element can be retained in the plug housing, but the pull-out force is insufficient leading to unintentional extraction
Solution Approach 1:
The side wall is designed with a resilient area that can dynamically deform during insertion and then elastic recovery to create high extraction force. The resilient area bends inward during insertion to allow the locating hook to pass, then springs back to engage the hook, creating a dynamic locking mechanism that provides high pull-out force while maintaining reliable retention.
Solution Approach 2:
The material properties of the side wall are changed by creating a resilient area with different mechanical characteristics than the rest of the housing. This resilient area has controlled elasticity that allows it to deform under insertion force and then recover to provide extraction force, changing the mechanical parameter of the side wall from rigid to resilient in the insertion region.
2Reliability
If high mounting forces are applied to secure the contact element, then the contact element is firmly retained, but the service life is reduced and production costs increase
Solution Approach 1:
The resilient side wall creates a dynamic insertion process where the material deforms elastically rather than requiring high static forces. The contact element is retained through the elastic recovery of the resilient area, not through forceful mechanical interference, thereby reducing mounting force requirements while maintaining secure retention and extending service life.
Solution Approach 2:
The resilient area changes the mechanical parameter of the side wall from rigid to elastic in the insertion region, allowing the side wall to deform and recover during insertion. This parameter change enables firm retention through elastic forces rather than high mounting forces, reducing stress on components and extending service life.
3Reliability
If high mounting forces are used to secure the contact element, then reliable retention is achieved, but production costs increase
Solution Approach 1:
The resilient area modifies the mechanical parameter of the side wall to be elastic rather than rigid, enabling reliable retention through material deformation and recovery. This eliminates the need for high-force mounting equipment and complex assembly processes, thereby reducing production costs while maintaining reliable contact element retention.
Solution Approach 2:
The resilient side wall performs the retention function through its own elastic properties without requiring additional active components or high-force external systems. The material itself provides the retention mechanism through elastic recovery, simplifying the manufacturing process and reducing production costs.
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
The design significantly increases the pull-out force, reduces mounting force requirements, and lowers production costs, meeting high safety standards for applications like the automobile industry while maintaining cost-effectiveness.
Implementation Method 1
The side wall of the contact chamber is resilient, at least in the area before the abutment
Data Source
AI summary
The invention relates to a plug-in connector (10) having at least one contact chamber (50) provided in a plug housing (12) for receiving a contact element (11) that provides at least one abutment (51, 52) for a locating element (41) arranged on the contact element (11). The locating element (41) is designed as an inelastic locating hook (41). The side wall (30, 31) of the contact chamber (50) is resilient, at least in the area before the abutment (51, 52), Further, a recess (36, 37) is provided in the plug housing (12) at least adjacent the resilient area of the side wall (30, 31).