Self-Ejecting Electrical Connector with Guided Locking Plunger
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Solution Overview
Problem
Existing electrical connection systems with self-ejecting features do not adequately guide the thrust member, and locking devices made from plastic can fail due to polymer creep, requiring additional features for self-ejection functions.
Innovation Solution
An electrical connector system featuring a first and second connector body with a flexible locking arm, a plunger, and compression springs that move between engaged and disengaged positions to securely connect and disconnect the connectors, utilizing a metallic clip to reduce polymer creep, and a guide channel to ensure proper alignment and separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If locking devices are made from plastic, then manufacturing cost and ease of manufacture are improved, but reliability deteriorates due to polymer creep over time
Solution Approach 1:
The locking device is constructed as a composite structure combining polymeric material (for the housing and plunger) with a metallic clip (providing creep-resistant locking features). This allows the device to maintain the manufacturing advantages of plastic while incorporating the dimensional stability and reliability of metal components that resist polymer creep.
2Ease of operation
If additional features are added to the male connector housing for self-ejection, then self-ejection function is improved, but device complexity increases
Solution Approach 1:
The connector system achieves self-ejection through the interaction between the spring-loaded plunger and the locking arm mechanism. When the connector is properly mated, the plunger is compressed and automatically pushes the locking arm to disengage the locking fin, causing the connectors to separate. This self-service mechanism eliminates the need for additional manual ejection features.
Solution Approach 2:
The plunger serves multiple functions: it provides connector position assurance by maintaining engagement during insertion, enables self-ejection when properly mated, and guides the locking arm during the ejection process. This multi-functionality reduces the need for separate components dedicated to each function.
3Ease of operation
If the plunger is not adequately guided, then ease of operation is improved, but manufacturing precision deteriorates due to misalignment during connection
Solution Approach 1:
The groove in the locking arm acts as an intermediary guiding feature that directs the plunger's movement path. As the plunger engages with the locking arm, the groove ensures proper alignment and guidance, preventing misalignment issues while maintaining ease of operation during connector mating.
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 system ensures proper connection and disconnection by using a spring mechanism to maintain engagement until locking features are fully engaged, providing connector position assurance and reducing the risk of polymer creep failure, thus ensuring reliable and automatic separation of connectors.
Implementation Method 1
a spring disposed between the plunger and the second connector body. This spring is configured to urge the plunger into the engaged position
Implementation Method 2
Compression of the spring causes the push surface on the flexible arm of the plunger to exert a force on the forward end of the first connector body
Implementation Method 3
a flexible locking arm defined by the second connector body configured to releasably engage the locking fin
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
An electrical connector system (100) includes a first connector body (104) defining a locking fin (106), a second connector body (1100 configured to receive the first connector body 9104), and a flexible locking arm (118) defined by the second connector body (110) configured to releasably engage the locking fin (106). A plunger (120) is slidably attached to the second connector body (110) and is moveable from an engaged position (122) in which the plunger (120) holds the locking arm (118) in engagement with the locking fin (106) to a disengaged position (122) in which the plunger (120) disengages the locking arm (118) from the locking fin (106). A spring (126) is disposed between the plunger (122) and the second connector body (110) and is configured to urge the plunger (120) into the engaged position (122).