Stage Pin Connector Sleeve Snap-Fit for Secure Contact Alignment
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Solution Overview
Problem
Existing indoor electrical connectors, such as stage pin connectors, face challenges in providing reliable and durable connections for dimmable power to stage lighting and equipment, particularly in withstanding repeated use and rough handling, while ensuring proper alignment and secure engagement of contact elements.
Innovation Solution
The design incorporates a housing with snap-fit connection features and a sleeve with corresponding snap-fit features, along with a hinge connection between housing members, to securely engage and align contact elements, ensuring impact resistance and high temperature durability, and utilizing non-conductive, high-temperature resistant materials like molded thermoset plastic for enhanced thermal insulation and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical connectors are used for indoor applications, then basic electrical connection is achieved, but they fail to provide reliable and durable connections under repeated use and rough handling
Solution Approach 1:
The connector is divided into multiple housing members (first housing member and second housing member) that can be assembled together. This segmentation allows each part to be optimized for specific functions - the first housing member provides structural support while the second housing member contains the contact elements, improving overall reliability and durability under repeated use
Solution Approach 2:
Alignment features are pre-formed on the housing members and contact elements before assembly. These pre-formed alignment features ensure proper positioning of contact elements during the assembly process, preventing misalignment that would reduce connection reliability and durability
2Reliability
If traditional connectors are used, then basic connection is provided, but they fail to ensure proper alignment and secure engagement of contact elements
Solution Approach 1:
Alignment features are designed with asymmetric geometries that provide directional guidance during assembly. The asymmetric shapes ensure that contact elements can only be inserted in the correct orientation, guaranteeing proper alignment and secure engagement without requiring high-precision manufacturing tolerances
Solution Approach 2:
Alignment features act as intermediary elements between the housing members and contact elements. These intermediate structures facilitate proper positioning and engagement, ensuring that contact elements are accurately aligned with conductor openings during assembly
3Strength
If conventional materials are used, then manufacturing is simple, but the connector lacks impact resistance and high temperature durability
Solution Approach 1:
The connector utilizes composite construction combining thermoset plastic material for the housing members with metal contact elements. The thermoset plastic provides impact resistance and thermal stability, while the metal contacts provide electrical conductivity. This composite approach achieves high strength and temperature durability without significantly increasing manufacturing complexity
4Temperature
If the connector design does not include thermal insulation, then manufacturing is simpler, but it fails to provide adequate thermal management for high temperature durability
Solution Approach 1:
Thermal insulation properties are localized to specific areas where needed - the thermoset plastic housing members provide thermal insulation around the conductive contact elements. This local application of insulating material provides adequate thermal management without requiring complex insulating structures throughout the entire connector
Data Source
AI summary
A stage pin electrical connector includes a housing having a first housing member and a second housing member. The first and second housing members are releasably connected together to define an interior, a conductor opening, a contact portion, and a contact opening. The contact portion includes a first snap-fit connection feature. A sleeve receives a contact member and has a second snap-fit connection feature configured to releasably mate with the first snap-fit connection feature.