Spring-Loaded Sheet Metal Locking Element for Device Plug
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Solution Overview
Problem
Existing device connection systems face inefficiencies in production and logistics due to the need for multiple device variants to accommodate different national electrical standards, often requiring additional costly elements like screws or spring clamps for secure connections, which can be cumbersome and expensive to implement.
Innovation Solution
A device connector with a spring-loaded sheet metal latching element that accommodates a partially circumferential gap, allowing for secure locking without additional locking steps, and a resilient can latching device that shares a recess with the sheet metal latching elements, enabling a one-piece injection molding production of the connector and socket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional locking elements such as screws or spring clamps are used to secure the connection, then the connection reliability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent integrates the locking function directly into the housing structure by forming locking protrusions and corresponding locking recesses as integral parts of the housing components. This merging of the locking mechanism with the housing eliminates the need for separate locking elements like screws or spring clamps, thereby maintaining connection reliability while reducing device complexity and manufacturing cost.
Solution Approach 2:
The housing structure itself provides the locking functionality through its geometric design. The locking protrusions and recesses are formed directly on the housing parts, allowing the housing to lock itself without requiring additional active locking components. This self-service approach ensures reliable connection while simplifying the overall device structure.
2Adaptability or versatility
If multiple device variants are produced to accommodate different national electrical standards, then the adaptability to different markets is improved, but the manufacturing efficiency and production cost worsen
Solution Approach 1:
The patent designs the housing with standardized locking features (locking protrusions and recesses) that can accommodate different electrical plug configurations. The universal housing structure allows a single base model to be adapted to various national electrical standards by simply changing the electrical components, rather than producing entirely different device variants, thereby maintaining manufacturing efficiency while achieving market adaptability.
Solution Approach 2:
The device is segmented into modular components where the housing structure with locking features remains standardized, while the electrical components can be varied to meet different national standards. This segmentation allows the universal housing to serve multiple market requirements without compromising production efficiency.
3Manufacturing precision
If a double locking hook is used to fix the device plug position, then the positioning accuracy is improved, but the compatibility with different sheet metal cutting technologies worsens
Solution Approach 1:
The patent employs locking protrusions and recesses with optimized geometric parameters that can be manufactured using various sheet metal cutting technologies. The dimensional parameters of these locking features are designed to maintain positioning accuracy while being compatible with different cutting methods, allowing flexibility in manufacturing processes without sacrificing precision.
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
This solution allows for a cost-effective, secure, and efficient connection system that can be easily adapted to different country-specific standards, reducing production costs and ensuring reliable locking without the need for extra locking mechanisms, while simplifying the manufacturing process.
Implementation Method 1
the sheet metal locking element is designed as a spring element and the gap is designed such that a gap thickness is provided between the sheet metal locking element and the external device assembly
Data Source
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Figure 3~4
AI summary
The invention relates to a device connector for snapping into an opening of a device housing sheet and for receiving a device socket, comprising a device connector housing, a device connector interior, and an electrical contacting element which extends from the device connector interior to an exterior area. The device connector housing includes an external device assembly and a sheet metal locking element. The sheet metal locking element has a partially circumferential gap, such that the sheet metal locking element is designed as a spring element, and the gap is designed such that a gap thickness is provided between the sheet metal locking element and the external device assembly for receiving the device housing sheet. During a snapping operation into the opening of the device housing sheet, the sheet metal locking element is springed into the device connector interior by contacting the device housing sheet forming the opening and is springed back upon snapping.the gap thickness essentially accommodates a portion of the device housing sheet metal.