Plug Vibration Protection via Slider Ramp Mechanism
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Solution Overview
Problem
Existing plug solutions for electromobility in motor vehicles face challenges in securing a stable and vibration-resistant electrical contact, particularly under high-voltage conditions, leading to wear and increased contact resistance due to inadequate attachment methods.
Innovation Solution
A plug design featuring a contact body and slider mechanism that provides vibration protection through a friction-locking and form-fitting connection, where the slider is guided in a sliding guide and interacts with the contact body via a ramp surface to secure the plug element within the housing, ensuring reliable retention and high contact extraction forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic clips are used to connect the plug element to the plug housing, then the plug can be easily manufactured, but the connection is not sufficiently resistant to vibrations
Solution Approach 1:
The connection system is divided into two functional parts: a plastic clip for easy attachment and a metal vibration protection element for secure fixation. The metal element is inserted through the plastic clip and engages with the plug housing, creating a segmented system where each component performs its specialized function - the plastic provides ease of manufacture while the metal provides vibration resistance
Solution Approach 2:
The connection mechanism combines two different materials with complementary properties: plastic (for ease of manufacture and insulation) and metal (for vibration resistance and mechanical strength). This composite approach allows the plastic clip to provide easy attachment while the metal vibration protection element provides the necessary mechanical strength to resist vibrations
2Reliability
If the plug element has relatively great wall thickness to guide high power current, then the electrical conductivity is improved, but the rigidity increases making plastic clips ineffective
Solution Approach 1:
The fastening function is segmented from the electrical conduction function. The plastic clip handles the electrical insulation and basic attachment, while the separate metal vibration protection element provides the mechanical compliance needed to accommodate the rigid, thick-walled plug element. This segmentation allows each component to be optimized for its specific function without compromise
3Reliability
If a box spring is used to secure the plug element, then mechanical and electrical contact is improved, but the attachment security is insufficient and production automation is problematic
Solution Approach 1:
Instead of using a spring mechanism that requires complex assembly and verification, the solution inverts the approach by using a simple insertion mechanism where the metal vibration protection element is pushed through the plastic clip and engages with the plug housing. This inverted approach simplifies the attachment process, making it suitable for automated production while maintaining secure contact
Solution Approach 2:
The plastic clip is designed as a simple, inexpensive component that can be easily manufactured and replaced if needed. While the metal vibration protection element provides the secure attachment, the plastic clip serves as an economical auxiliary component that facilitates easy assembly and can be disposed of or replaced without significant cost
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 solution effectively secures the plug element against vibrations, minimizing wear and contact resistance, and allows for scalable and automated production, enhancing the reliability and efficiency of electrical connections in motor vehicle applications.
Implementation Method 1
Via a ramp surface, the slider cooperates with the contact body which is formed such that the contact body is pushed against the plug element when the slider is slid into the plug housing
Implementation Method 2
A plug design featuring a contact body and slider mechanism that provides vibration protection through a friction-locking and form-fitting connection
Data Source
Figure 1
Figure 2~3A
Figure 3B~3C
AI summary
The present invention relates to a plug with a plug housing (2) and an electrically conductive plug element (12) for a mating plug element. A vibration protection according to the present invention, which can be attached in a reliable manner, has a contact body (28) which cooperates with the plug element (12), and a slider (30) which is displaceably guided in a sliding guide (90) which is formed on the plug housing (2) and cooperates with the contact body (28) via a ramp surface (76) such that the contact body (28) is pushed against the plug element (12) when the slider (30) is slid into the plug housing (2).