Electrical Plug-In Connector Automatic Tear-Off Mechanism
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Solution Overview
Problem
Existing electrical connectors face challenges in easy connection and disconnection, wear, jamming, and unwanted bending of spring parts, which impairs functionality and safety, especially under unforeseen tensile forces.
Innovation Solution
A connector design featuring a spring element engaging with a guide link in a plug part, with a tear-off elevation that allows automatic separation when a tensile force exceeds a threshold, combined with a cap sleeve for secure positioning and adjustable tear-off force, enabling both user-guided and automatic disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the spring element interacts with the spring parts and guide slot in the known connector design, then the automatic tear-off functionality is achieved, but the tear-off functionality works only to a limited extent and plugging is tedious and susceptible to wear
Solution Approach 1:
The connector is divided into distinct functional components: a cap sleeve for user-guided disconnection, a spring element for automatic tear-off, and a guide link with tear-off elevation. This segmentation allows each component to specialize in its function, improving both reliability of automatic tear-off and ease of user operation.
Solution Approach 2:
The guide link with tear-off elevation acts as an intermediary between the spring element and the connector housing. It provides a controlled path for the spring part to follow during automatic tear-off, ensuring reliable separation while preventing unwanted jamming and splaying of spring parts.
2Reliability
If the spring parts and guide slot have complex geometries to enable automatic tear-off, then automatic separation is possible, but undesired jamming and splaying as well as bending of spring parts occur, which impairs functionality
Solution Approach 1:
The guide link features curved and rounded geometries instead of sharp angles. The tear-off elevation has a smooth curved surface that guides the spring part through a controlled path, preventing sudden movements that would cause jamming, splaying, or bending of the spring parts.
Solution Approach 2:
The guide link geometry is optimized with specific parameters: the tear-off elevation has a controlled height and curvature radius that match the spring part dimensions. This parameter optimization ensures the spring part follows the intended path during automatic tear-off without deviating into jamming or splaying modes.
3Reliability
If the spring element is exposed and accessible for automatic tear-off, then automatic separation can occur, but the spring element protrudes and creates wear and positioning issues
Solution Approach 1:
The spring element is nested inside the cap sleeve, which serves as a protective housing. The cap sleeve provides a defined space for the spring element, preventing it from protruding and creating wear issues, while still allowing automatic tear-off to occur through the structured interaction between the spring part and guide link.
Solution Approach 2:
The cap sleeve acts as an intermediary structure that houses the spring element and provides a stable mounting position. This intermediary structure eliminates direct exposure of the spring element, reducing wear and improving positioning stability while maintaining automatic separation functionality.
4Adaptability or versatility
If the connector allows both user-guided and automatic disconnection, then multi-optional disconnection is achieved, but the device complexity increases
Solution Approach 1:
The cap sleeve serves multiple functions: it protects the spring element, provides a user grip for manual disconnection, and works with the guide link to enable automatic tear-off. This multi-functionality reduces the need for separate components for each disconnection mode, thereby limiting the increase in device complexity.
Solution Approach 2:
The manual disconnection mechanism (cap sleeve rotation) and automatic disconnection mechanism (spring element with guide link) are merged into a unified system. The same cap sleeve and guide link structure supports both user-guided and automatic separation, reducing overall device complexity compared to having separate mechanisms for each mode.
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 connector ensures safe, reliable, and low-wear automatic disconnection, preventing damage from unintended tensile forces and allowing precise control over separation, while maintaining connector stability and longevity.
Implementation Method 1
at least one spring element (19), which, in order to connect the plug parts (1, 3), engages with at least one spring part (25) in a guide link (47) in the second plug part (3)
Implementation Method 2
the spring element is designed such that when a tensile force value greater than a tear-off force threshold value occurs on at least one of the two connector parts in the assembled state, the connector parts are automatically separated
Implementation Method 3
A tear-off elevation (50) is formed on this guide slot (47), which the spring part (25) engages behind when the plug parts (1, 3) are in the assembled state
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a plug-in connector (2) comprising a first (1) and a second plug part (3) which can be reversibly coupled and disconnected, wherein a connection device is designed that has at least one spring element (19), at least one spring piece (25, 26, 27) of which engages with a sliding guide (47) in the second plug part (3) in order to connect the plug parts (1, 3). The sliding guide (47) and the spring element (9) are designed such that the plug parts (1, 3) are automatically disconnected when a release threshold value is exceeded. A raised release element (50) which is embraced by the spring piece (25, 26, 27) in the plugged state of the plug parts (1, 3) is formed on the sliding guide (47). Said raised release element (50) is rectilinear in the circumferential direction around the longitudinal axis (A) and extends on the same axial sectional level across the width of the release element when viewed in the axial direction in such a way that when a tensile force that is greater than the release threshold value is applied to the plug parts (1, 3), the spring piece (25, 26, 27) is guided over the raised release element (50) exclusively in the axial direction in order to automatically disconnect the plug parts (1, 3). The invention also relates to a method for connecting and disconnecting plug parts (1, 3).