Push-in Electrical Connector with Visual Seating Indicators
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Solution Overview
Problem
Existing electrical connectors for DC power supplies require complex manufacturing processes, are limited to specific wire sizes, and lack visual confirmation of proper seating, leading to potential backout issues.
Innovation Solution
A push-in type electrical connector with a flexible housing and cap design that accommodates multiple conductor sizes, featuring hinged exterior tabs, snap-fit hooks with visual indicators for proper seating, and conductive contacts to ensure secure engagement and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single piece molded connector housing with through holes is used, then the connector provides structural integrity and contact retention, but the manufacturing process becomes complicated and time-consuming
Solution Approach 1:
The connector housing is divided into a front housing and a rear housing that can be manufactured separately and then assembled together. This segmentation allows each housing piece to be manufactured using simpler processes without requiring complex through-hole boring operations, while still maintaining the structural integrity and contact retention functionality when assembled.
Solution Approach 2:
The contact is inserted into and nested within the front housing, which then nests within the rear housing. This nested structure allows the contact to be retained securely while avoiding the need for complex through-hole boring operations in a single-piece housing, simplifying the manufacturing process.
2Device complexity
If cylindrical conductors are used in the connector, then the connector provides simple structure, but the wire size acceptance is limited
Solution Approach 1:
The contact design with the inclined surface and resilient finger can accommodate multiple wire sizes and conductor types. The resilient finger can flex to accommodate different conductor diameters, and the inclined surface provides a universal interface that works with various wire configurations, making the connector versatile without requiring complex adjustable mechanisms.
Solution Approach 2:
The contact uses a resilient finger that can change its physical state by flexing and deforming elastically. This parameter change allows the contact to adapt to different wire sizes within a range, providing versatility while maintaining a simple cylindrical conductor design. The resilient material properties enable the contact to accommodate variable conductor dimensions.
3Ease of manufacture
If the connector lacks visual indication of proper seating, then the manufacturing process is simpler, but the risk of conductor backout increases
Solution Approach 1:
The resilient finger includes a visual indicator that changes position or color to indicate proper conductor seating. When the conductor is properly inserted, the resilient finger deflects to a specific position that provides visual confirmation through color change or position indication, ensuring reliable seating without complicating the manufacturing process.
Solution Approach 2:
The resilient finger provides immediate feedback to the operator during assembly by deflecting when the conductor is properly inserted. This mechanical feedback system confirms proper seating in real-time during the assembly process, preventing backout issues while keeping the manufacturing process simple and straightforward.
4Productivity
If a push-in type contact is used, then the assembly process is simplified and multiple wire sizes are accepted, but visual confirmation of proper seating is needed
Solution Approach 1:
The resilient finger incorporates a visual indicator that provides color change or position-based visual confirmation when the conductor is properly seated in the push-in contact. This resolves the information loss by providing immediate visual feedback that the high-productivity push-in assembly was successful, preventing backout without slowing down the assembly process.
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 simplifies manufacturing, accepts a range of wire sizes, provides visual confirmation of proper seating, and ensures secure wire retention, reducing the risk of backout and improving assembly efficiency.
Implementation Method 1
a resilient contact (72) at one end
Implementation Method 2
front housing (12) having a wire connect portion (16) that defines an interior space (20)
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
An electrical connector includes a housing having outwardly extending sleeves for connection with a corresponding connector. The housing defines an aperture extending through the extending sleeves, and an electrically-conductive contact is retained within the interior space of the housing and extending into the aperture. The electrically-conductive contact has an end comprising a contact portion within the aperture and an opposite end comprising a push-in type contact element. A cap retains the contact within the interior space, enclosing the interior space, and defining a port to allow insertion of a conductor of various construction therthough.