Quick-Connect Power Connector Locking for Vibration-Safe Mating
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Solution Overview
Problem
Existing electrical connectors face challenges such as high manufacturing costs, complex assembly processes, potential for foreign object debris, and unreliable connections due to threaded components, which can lead to improper mating and disconnection under environmental stress like vibration.
Innovation Solution
A quick connect electrical connector design featuring a housing body with a post receiving passage, a locking release member, and a locking spring member that provides a visual indication of proper mating and secures the connection without tools, preventing rotation and ensuring a reliable electrical connection across varying temperatures and vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If threaded components (nuts and bolts) are used to secure the electrical connector to the terminal post, then the connection can be securely retained and provide high contact forces, but the manufacturing cost increases, assembly time increases, and the complexity of the connection increases
Solution Approach 1:
The patent removes threaded components (nuts and bolts) from the electrical connector assembly, extracting the problematic elements that caused complexity and cost issues. The quick-connect mechanism achieves secure retention without requiring separate fastening hardware, directly resolving the contradiction between connection security and device complexity.
Solution Approach 2:
The electrical connector incorporates an integrated quick-connect mechanism that automatically secures itself to the terminal post without requiring external fasteners or complex assembly procedures. The connector's own structure provides the retention function, eliminating the need for separate nuts and bolts and reducing overall system complexity.
2Reliability
If threaded components are used to secure the electrical connector, then the connection can be maintained under vibration, but the assembly process becomes more time-consuming and requires specialized tools like torque wrenches
Solution Approach 1:
The quick-connect mechanism is self-contained within the connector housing, allowing installation without external tools or specialized equipment. The integrated design enables operators to complete connections rapidly by simply engaging the connector with the terminal post, eliminating the time required for threading and torque application while maintaining vibration resistance.
3Reliability
If multiple parts are used to create the electrical connection, then the connection can be secured reliably, but the cost increases and the possibility of foreign object debris (FOD) increases
Solution Approach 1:
The patent combines multiple separate components (connector housing, contact elements, and retention mechanism) into a single integrated quick-connect assembly. This merging reduces the number of discrete parts that could become loose or generate foreign object debris, while the integrated design ensures reliable electrical connection and mechanical retention through coordinated interaction of the combined components.
4Reliability
If threaded interconnection is used, then the electrical connection can be secured, but disassembly for periodic repair and maintenance becomes difficult
Solution Approach 1:
The patent removes threaded fasteners and complex fastening mechanisms from the connector design, extracting the elements that made disassembly difficult. The simplified quick-connect mechanism allows for rapid removal and reinstallation of connectors, making periodic repair and maintenance straightforward while maintaining secure operational connections.
5Ease of operation
If simple insertion of the connector onto terminal posts is used, then the assembly is simple and quick, but the connectors may not be properly positioned and locked in place
Solution Approach 1:
The quick-connect mechanism incorporates automatic positioning and locking features that activate during the simple insertion process. As the connector is pushed onto the terminal post, the integrated mechanism self-adjusts to ensure proper alignment and engages retention elements that lock the connection in place, maintaining both operational simplicity and connection reliability.
Solution Approach 2:
The connector design includes visual or tactile feedback mechanisms that indicate when proper positioning and locking have been achieved. This feedback confirms to the operator that the simple insertion process has successfully resulted in a securely locked connection, eliminating the need for complex verification procedures while ensuring reliable installation.
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 simplifies installation, reduces costs, enhances reliability by ensuring proper mating and securing connections, and maintains electrical integrity under environmental stress, suitable for high amperage applications.
Implementation Method 1
a locking spring member moveable between a first position in which the locking spring member engages the locking release member and a second position in which the locking spring member disengages the locking release member
Data Source
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AI summary
An electrical connector and system for connecting to a terminal post. The electrical connector includes a housing body, a contact and a locking release member. The housing body includes a post receiving passage for receiving the terminal post therein. The contact is provided in the post receiving passage and is positioned about the circumference of the post receiving passage. The contact will make an electrical engagement with a terminal post inserted into the post receiving passage regardless of the orientation of the terminal post with respect to the contact. The electrical connector which prevents the improper mating of the connector to the post, prevents unwanted rotation of the connector, provides a visual indication that the proper connection is secured and provides a secondary lock to ensure that unwanted unmating of the connector does not occur.