Quick Connect Power Connector Vibration Resistance
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Solution Overview
Problem
Existing electrical connectors for high-vibration and high-temperature applications, such as those in military and aviation, face challenges with costly threaded components, complex assembly, potential for foreign object debris, and unreliable connections due to misalignment or incomplete mating, which can lead to system failures under environmental stress.
Innovation Solution
A quick-connect electrical connector with a housing body, a contact that engages regardless of orientation, and a locking slide with a radiused locking surface and resilient latching arms that ensure secure engagement and provide visual confirmation of proper mating, eliminating the need for tools and loose components.
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 strength and reliability are improved, but the assembly complexity, manufacturing cost, and assembly time increase significantly
Solution Approach 1:
The patent removes the threaded fastening components (nuts and bolts) from the connector assembly, replacing them with a simplified bayonet-style coupling mechanism. This extraction of unnecessary components directly reduces assembly complexity while maintaining connection reliability through the specialized geometric engagement of the connector housing with the terminal post.
Solution Approach 2:
Instead of using external threaded fasteners to secure the connector, the invention inverts the approach by integrating the locking mechanism directly into the connector housing itself. The housing includes built-in features that engage with the terminal post through rotational and axial movements, eliminating the need for separate fastening components.
2Reliability
If multiple separate parts are used to create the electrical connection, then the connection can be secured reliably, but the risk of foreign object debris (FOD) increases and the assembly cost increases
Solution Approach 1:
The patent combines multiple separate components (housing, contact, and locking mechanism) into a single integrated connector assembly. This merging eliminates loose parts that could become foreign object debris while maintaining reliable connection security through the integrated design where all components work together as one unit.
Solution Approach 2:
While reducing the number of parts, the invention strategically segments the connector into functional zones within the integrated housing - the electrical contact area, the locking engagement area, and the sealing area. This segmentation allows each function to be optimized independently while maintaining overall simplicity and reducing FOD risk.
3Reliability
If threaded fasteners are used to secure the connector, then the connection can withstand vibration, but the nuts may rotate off during vibration exposure leading to connection failure
Solution Approach 1:
The connector housing includes self-aligning and self-locking features that automatically ensure proper engagement during assembly. The bayonet-style coupling with its specific geometric profile ensures that the connector self-secures to the terminal post with a definitive locked position, eliminating the need for torque wrenches or specialized maintenance tools while maintaining vibration resistance.
4Reliability
If a latch assembly is added to provide visual confirmation of proper mating, then the reliability of connection is improved, but the device complexity increases
Solution Approach 1:
The patent incorporates visual indicators directly into the connector housing structure using color-coded features or position-dependent visibility of marked areas. As the connector is assembled and locked to the terminal post, the housing rotates or moves to a position where specific colored indicators become visible, providing immediate visual confirmation of proper mating without requiring separate latch assemblies or additional mechanical confirmation mechanisms.
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 provides a reliable, cost-effective, and secure electrical connection that withstands environmental conditions, including vibration, and ensures proper mating without the need for tools, reducing the risk of system failures and foreign object debris issues.
Implementation Method 1
The locking latch has a pair of resilient latching arms which extend from the locking section, the resilient latching arms being mounted in the locking slide to allow them to be resiliently deformed
Data Source
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AI summary
An electrical connector (10) is provided for connecting to a terminal post (100), and has a housing body (12) having a post receiving passage (14) for receiving the terminal post (100) therein. A contact (28) is provided in the post receiving passage (14), and the contact (28) is arranged to be in electrical engagement with the terminal post (100) inserted into the post receiving passage (14) regardless of the orientation of the contact (28) with respect to the terminal post (100). A locking slide (50) is moveably mounted to the housing body (12), the locking slide (50) being moveable between a prelocked position and a locked position. The locking slide (50) has a locking latch (66), and the locking latch (66) has a locking surface which cooperates with a recess (104) of the terminal post (100) when the locking slide (50) is in the locked position.