Self-rejecting automotive harness connector with helical spring slider
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connectors for mission-critical safety devices in vehicles often fail to ensure complete and reliable connection, leading to potential failures in safety systems due to incomplete mating, which can result in disconnection under vibration or shock, and lack effective mechanisms for self-rejection from incomplete mating attempts.
Innovation Solution
A connector assembly that utilizes a helical spring-driven slider to store insertion force, allowing automatic self-rejection if the mating is incomplete, providing a visually distinct disconnected state and ensuring electrical disconnection, while also offering a tactile and audible signal for correct mating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If locking means are used to prevent disconnection, then connection reliability is improved, but assembly error risk increases due to false confidence from electrical continuity checks
Solution Approach 1:
The patent introduces an intermediary verification mechanism (visual inspection features and tactile feedback) between the electrical connection and the locking mechanism. This intermediary system provides independent confirmation of complete mating, preventing false confidence from electrical continuity checks alone while maintaining connection reliability.
Solution Approach 2:
The patent implements feedback mechanisms including visual indicators (such as alignment features, color codes, or transparent sections) and tactile feedback (such as detent clicks or resistance changes) that confirm complete mating has occurred. This feedback loop ensures assembly accuracy by providing immediate verification that both electrical and mechanical connections are properly established.
2Ease of operation
If visual inspection is used to verify connection, then assembly verification is simplified, but detection accuracy decreases due to inability to detect incomplete mating
Solution Approach 1:
The patent employs color changes or color-coded features as visual indicators of connection status. Different colors or color patterns indicate different states (e.g., connected vs. disconnected, properly mated vs. improperly mated), enabling both ease of visual inspection and accurate detection of connection completeness.
Solution Approach 2:
The patent employs color changes or color-coded features as visual indicators of connection status. Different colors or color patterns indicate different states (e.g., connected vs. disconnected, properly mated vs. improperly mated), enabling both ease of visual inspection and accurate detection of connection completeness.
3Loss of time
If electrical continuity checks are performed, then connection verification is quick, but reliability decreases due to false positives from partial mating
Solution Approach 1:
The patent implements preliminary mechanical interlocking features (such as guide pins, alignment keys, or interlocking lugs) that must be properly engaged before electrical contacts can make connection. This preliminary action ensures that only complete matings allow electrical continuity, eliminating false positives while maintaining quick verification.
Solution Approach 2:
The patent segments the connection verification into multiple independent checks: mechanical interlocking verification (visual/tactile) and electrical continuity verification. This segmentation allows each aspect to be verified independently and quickly, with both required for complete connection assurance, preventing false positives from partial matings.
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 assembly ensures reliable and complete electrical connections by automatically disengaging from incomplete mating attempts, providing a clear visual and tactile indication of proper installation, thus preventing failures in mission-critical systems.
Implementation Method 1
A connector assembly that utilizes a helical spring-driven slider to store insertion force
Data Source
AI summary
A plug-in connector for connecting to a receptacle including a housing including fins, at least one electrically conductive terminal at least partly situated in the housing and defining a mating axis and a mating direction, cantilevered locking beams arranged in the housing, a slider slidingly coupled to the housing and including blocking beams extending in the mating direction, a compressive member arranged to urge the slider outward away from the housing in the mating direction. The fins are situated to engage with the blocking beams during an initial stage of relative movement between the housing and the slider against a bias of the compressive member and allow inward deflection of the locking beams. The blocking beams are configured to prevent inward deflection of the locking beams after a final stage of the relative movement between the housing and the slider.