Smart Garment Connector Locking Structure for Wash-Durable Coupling
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Solution Overview
Problem
There is a need for durable, convenient, and accurate smart garments and components that provide reliable electrical and mechanical connections, while being resistant to external forces, dust, fouling, and corrosion, and capable of withstanding washing and drying.
Innovation Solution
The development of an electrical connector system with a housing, receptacle, and connector plug that provides high-quality mechanical and electrical connections, resistant to separation, corrosion, and fouling, and configured for easy handling and manufacturing, with features like alignment mechanisms and compression springs to ensure secure coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the connector components are made small to fit in garments, then the form factor is reduced and comfort is improved, but the ease of handling and manipulation by the user deteriorates
Solution Approach 1:
The connector components have non-uniform geometry with specific regions optimized for different functions: the body portion is compact for comfort, while the mating portion has extended features (tabs, recesses, alignment features) that facilitate easy handling and manipulation. This local differentiation allows the connector to be both small overall and easy to handle.
2Reliability
If the connector provides strong resistance to mechanical separation, then the reliability of electrical connection is improved, but the ease of user separation when desired deteriorates
Solution Approach 1:
The connector uses spring-loaded electrical contacts that provide dynamic mechanical engagement. The springs maintain constant contact pressure for reliable electrical connection and resistance to separation, while allowing the connector to be deliberately separated by applying sufficient force in the correct direction. The dynamic spring mechanism adapts to varying forces during normal use versus deliberate user separation.
3Reliability
If the connector is designed for durable, continuous electrical coupling, then the reliability is improved, but the complexity of ensuring robust connection deteriorates
Solution Approach 1:
The connector integrates multiple functions into a single unified structure: the body houses both the electrical contacts and the mechanical engagement features (tabs and recesses). The mating portion combines electrical contact surfaces with structural elements that provide alignment and retention. This merging of functions reduces the number of separate components needed while ensuring reliable electrical coupling.
4Ease of manufacture
If the connector components are made easily manufacturable, then the productivity is improved, but the manufacturing precision required for reliable connection deteriorates
Solution Approach 1:
The connector uses asymmetric tab and recess geometries that provide built-in alignment guidance during assembly. The asymmetric shapes naturally guide the mating components into the correct orientation and position, reducing the precision requirements for manufacturing while ensuring reliable connection. This geometric constraint system compensates for normal manufacturing tolerances.
Data Source
AI summary
An electrical connector system that can be used to couple a smart garment sensor harness to a control component. Embodiments include a connector plug on an electrical wire cable of the sensor harness and a connector socket on the control component. The connector plug includes a body that mates with a receptacle of the connector socket in a releasable manner. The connector plug and connector socket are configured to prevent removal of the connector plug from the connector socket in the direction that the cable extends from the body of the connector plug.