Protective Plug Leaf Spring Retention for Connector Sealing
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Solution Overview
Problem
Existing protective plugs for connectors fail to reliably seal openings due to gaps between retaining tabs and recesses, leading to insufficient retention force, ease of skewing, and reduced dustproof and electromagnetic interference shielding effectiveness.
Innovation Solution
A protective plug design featuring leaf springs with elastic arms and contact surfaces that apply a rearward force upon insertion, providing a clicking feedback and enhanced retention, along with a conductive layer for dustproof and electromagnetic shielding, and alignment features for secure fitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the plug uses a simple recess structure to accommodate the retaining tab, then the device complexity is reduced, but the reliability of sealing and retention force is insufficient
Solution Approach 1:
The patent introduces elastic arms with spring elements that dynamically adapt to the retaining tab during insertion. The elastic arms deform elastically to accommodate the tab and then exert continuous retaining force, transforming a static recess structure into a dynamic retention mechanism that ensures reliable sealing without increasing overall structural complexity.
Solution Approach 2:
The plug structure is segmented into multiple functional components: the main body, multiple elastic arms with separate spring elements, and individual retaining tabs. This segmentation allows each component to perform its specific function independently, improving overall reliability while keeping each individual component relatively simple.
2Ease of manufacture
If the plug relies on perpendicular spring force from the retaining tab, then the ease of manufacture is improved, but the retention force in the inserting direction is insufficient
Solution Approach 1:
The patent transforms the force application from a single perpendicular dimension to multiple dimensions. The elastic arms are configured to convert the perpendicular spring force into a component force that acts in the inserting direction. This dimensional transformation allows the retaining tab to provide effective retention force along the insertion axis while maintaining the simple perpendicular spring mechanism.
Solution Approach 2:
The patent changes the geometric parameters of the elastic arms and their mounting angles to optimize the force transmission. By adjusting the orientation and dimensions of the elastic arms, the system converts the perpendicular spring force into an effective retaining force in the inserting direction, improving retention without complicating the spring mechanism itself.
3Ease of operation
If the plug uses a simple insertion structure without guiding features, then the ease of operation is improved, but the plug is easy to skew when subjected to external force
Solution Approach 1:
The patent introduces asymmetric guiding oblique surfaces on the elastic arms that engage with corresponding features on the retaining tab. These asymmetric surfaces provide directional guidance during insertion, preventing skewing while maintaining ease of operation. The oblique surfaces naturally guide the plug into the correct orientation without requiring complex alignment features.
4Ease of manufacture
If the plug lacks a conductive layer, then the ease of manufacture is improved, but the electromagnetic interference shielding capability is reduced
Solution Approach 1:
The patent combines a non-conductive base material (for ease of manufacturing and insulation) with a conductive layer (for EMI shielding). This composite structure allows the plug to benefit from both materials: the base material provides structural integrity and ease of molding, while the conductive layer provides electromagnetic shielding capability. The conductive layer can be applied as a coating or plating on the existing plug structure.
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 plug ensures reliable sealing, resistance to external forces and vibrations, and improved user feedback during insertion, while maintaining dustproof and electromagnetic shielding capabilities.
Implementation Method 1
each leaf spring has an elastic arm extending rearwardly and inwardly, the elastic arm has a contact portion... the contact portion of the leaf spring contacts the leaf spring acting surface portion and applies a component force toward the rear
Implementation Method 2
a conductive layer is provided on the surfaces of the protective plug for contacting the plurality of leaf springs
Data Source
AI summary
A protective plug is provided for a connector that includes a shielding cage with an insertion space therein and a front end opening communicating with the insertion space, the front end opening has a plurality of leaf springs, each leaf spring has an elastic arm extending rearwardly and inwardly, the elastic arm has a contact portion. The protective plug includes a cover body to cover the front end opening and an insertion body, the insertion body has at least one first contact surface facing the corresponding leaf spring, the first contact surface has a leaf spring acting surface portion extending forwardly and inwardly, after the protective plug is inserted to the insertion space of the shielding cage, the contact portion of the leaf spring contacts the leaf spring acting surface portion and applies a component force toward the rear to the leaf spring acting surface portion.