Rotatable Coupling Ring Electrical Connector with Axial Threading
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Solution Overview
Problem
Conventional male plug-type connectors face challenges in providing repeatable, consistent connections with female receptacle connectors, especially in applications requiring fine control and minimizing physical stress on pins, which can lead to damage and unreliable connections, particularly in industrial and military settings where multiple connections and disconnections are necessary.
Innovation Solution
A connector design that uses a controlled on-axis force with a stop catch for full pin insertion and extraction, alignment pins for configuration alignment, and a rotatable coupling ring with triple start threads to provide leverage and control, minimizing torque and ensuring safe, reliable connections by preventing excessive force on pins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional levers are used to establish electrical connection and disconnection, then ease of operation is improved, but stress and bending of connector pins worsens due to off-axis moments
Solution Approach 1:
Instead of using a lateral lever motion to engage/disengage connectors, the patent inverts the mechanism by using axial threading motion. The threaded coupling member engages the pin plunger axially, converting rotational motion into linear motion that pushes or pulls the contact pins directly along their insertion axis, eliminating off-axis moments
Solution Approach 2:
The patent replaces the conventional mechanical lever system with a threaded mechanical system. The threaded coupling member with internal threads engages the pin plunger through axial threading, providing a more controlled and precise mechanism that eliminates the harmful off-axis forces generated by lever arms
2Productivity
If repeated connecting and disconnecting operations are performed, then testing capability is improved, but connector damage and reliability worsens
Solution Approach 1:
The patent incorporates a pin plunger mechanism that allows controlled axial movement of contact pins. This plunger system acts as a cushioning element that absorbs mechanical shocks and stresses during repeated connection/disconnection cycles, protecting the rigid contact pins from damage while enabling frequent testing operations
3Manufacturing precision
If fine control over pin engagement is required, then connection precision is improved, but device complexity worsens
Solution Approach 1:
The patent employs a dynamic threaded coupling mechanism where the threaded coupling member can rotate and translate axially to control the pin plunger position. This dynamic system provides fine control over pin engagement by allowing incremental adjustments through thread rotation, enabling precise control without requiring overly complex 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 ensures reliable, repeatable connections with minimal pin stress, extending the connector's service life and facilitating easy use in challenging environments, including those with restricted accessibility and high vibration conditions.
Implementation Method 1
a rotatable coupling ring with triple start threads to provide leverage and control
Implementation Method 2
triple start threads to provide leverage and control
Data Source
AI summary
An anchored 522 male electrical connector is provided. A stationary housing 520 is combined with a coupling ring 540 to form an outer housing. An internal plunger 560 is housed in and spans the length of the outer housing. The stationary housing 520 mounts onto an anchoring surface via an anchor mount 522, while the coupling ring 540 is free to rotate about the internal plunger 560. The coupling ring is rotated via a hand grasp 441. The coupling ring rotation 442, 443 translates into forward and aft movement of the pin assembly 515. The connector provides forward 520-1 and backward stops 520-4 for limiting pin insertion and extraction moves to desired distances. Rotation via triple start threads 548, 525 readily overcomes insertion and extraction resistance of a bulky multi-pin assembly 515 and provides a smooth and controlled electrical connection. The connector may be sized to meet multi-pin connector needs or military standards.