Self-locking Locking Arm for Electric Plug Connector
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Solution Overview
Problem
Electrical connectors for motor vehicle restraint systems face challenges in ensuring high safety standards for plugging and contact security over time, especially under extreme conditions, while also requiring cost reduction, lightweight design, easy assembly, minimal space usage, intuitive unlocking, low insertion forces, clear feedback, and resistance to external influences.
Innovation Solution
The electrical connector features self-locking locking arms that reinforce engagement with the socket, providing a strong latching force that increases with tensile force until destruction, and can be canceled by actuating the locking arm, allowing for easy release. This design eliminates the need for secondary locking mechanisms, uses a space-saving geometry, and offers clear acoustic and tactile feedback through a curved locking arm and latching lug configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a secondary locking mechanism is added to ensure plugging security, then reliability improves, but device complexity increases
Solution Approach 1:
The patent removes the secondary locking mechanism from the connector design, relying instead on the self-locking effect of the locking arm geometry. This extraction of the unnecessary component simplifies the overall device while maintaining plugging security through the spring-loaded locking arm that automatically engages and resists unintended release.
Solution Approach 2:
The locking arm is designed to be self-locking through its geometric configuration and spring force. The locking arm automatically engages with the locking section of the socket and maintains the locked position without requiring additional locking components. The system serves itself by using the spring force and geometry to maintain security without external intervention or complex mechanisms.
2Reliability
If the locking arm geometry is optimized for self-locking, then reliability improves, but ease of operation worsens
Solution Approach 1:
The locking arm incorporates a spring element that provides dynamic characteristics to the system. The spring allows the locking arm to flex and return to its engaged position, providing automatic re-engagement if disturbed. For unlocking, the user applies force to overcome the spring force temporarily, after which the spring returns the arm to its locked position, maintaining reliability while allowing controlled operation.
Solution Approach 2:
The patent optimizes parameters such as spring force, locking arm geometry, and engagement depth to achieve the desired balance. By adjusting these parameters, the design ensures that normal operation allows easy unlocking when intentionally actuated, while unintended release remains difficult due to the optimized self-locking geometry and spring characteristics.
3Reliability
If the locking arm spring force is increased to prevent unintended release, then reliability improves, but insertion force increases
Solution Approach 1:
The locking arm is designed to engage the locking section of the socket during the normal insertion process itself. As the connector is pushed into the socket, the locking arm automatically deflects and then snaps into the engaged position, completing the locking action as part of the insertion sequence. This preliminary action during insertion eliminates the need for separate high-force operations while maintaining reliable locking.
Solution Approach 2:
The spring-loaded locking arm provides dynamic engagement during insertion. The spring allows temporary deflection during the insertion process, then returns the arm to its locked position with a snapping motion. This dynamic behavior enables reliable locking without requiring excessively high insertion forces, as the spring absorbs and releases energy during the engagement 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 solution ensures secure and reliable connection under extreme conditions, reduces production costs, and maintains performance without signs of fatigue over long-term use, while allowing for easy assembly and intuitive operation, meeting safety and cost requirements.
Implementation Method 1
a deformation of the locking arm for springing is provided in a lower section of the spring arm in the insertion direction S (spring section below the latching section)
Data Source
AI summary
The electrical plug connector has a housing (10) that is provided with locking arm (11,11'). The locking arm is provided to lock/unlock of housing with socket (50) with respect to applied tensile force for releasing the connector main portion from socket. The locking arm is provided with latching portion (12,12') for engaging locking portion (51,51') of the socket.