Tapered Electrical Connector Plug for Lateral Force Resistance
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Solution Overview
Problem
Electrical connectors are prone to damage and can cause adverse events, such as pulling electrical devices off surfaces, when subjected to lateral forces, as they do not securely engage with sockets.
Innovation Solution
The design includes a plug with a recessed contact and socket configuration where the plug's width narrows from the back to the front, and a socket with a cavity that decreases in width from the opening to the back, allowing the plug to rotate and slide while maintaining electrical contact, featuring a retention feature with a recessed area and mesa to secure the plug within the socket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrical connector uses a traditional straight plug design, then the structure is simple and easy to manufacture, but the connector is prone to damage and can cause adverse events when subjected to lateral forces
Solution Approach 1:
The plug is designed with a tapered shape that allows it to dynamically adjust its position within the socket. The narrowing width from back to front enables the plug to rotate and slide within the cavity, transforming the rigid static connection into a dynamic adaptive connection that can absorb lateral forces without damage.
Solution Approach 2:
The plug features an asymmetric tapered geometry where the width varies along its length, creating a non-uniform shape that optimizes engagement with the corresponding asymmetric cavity in the socket. This asymmetric design provides directional stability while allowing controlled movement to dissipate lateral forces.
2Reliability
If the plug width is uniform throughout, then the manufacturing process is simpler, but the connector cannot securely engage with the socket under lateral forces
Solution Approach 1:
The plug's width parameter is deliberately varied along its length, transitioning from a wider back to a narrower front. This parameter change creates a tapered profile that enhances engagement security by providing a wedging action and allowing the plug to lock into the cavity, while the gradual transition keeps manufacturing feasible through standard forming processes.
3Reliability
If the socket cavity width is constant, then the socket structure is simpler, but the plug cannot rotate and slide to maintain secure electrical contact under lateral forces
Solution Approach 1:
The socket cavity is designed with an asymmetric tapered shape that mirrors the plug's geometry, creating a complementary fit. This asymmetric design enables the plug to rotate and slide within the cavity while maintaining secure electrical contact, as the varying width provides guiding surfaces and engagement points that stabilize the connection under lateral forces.
Data Source
AI summary
According to an example embodiment, an electrical connector may include a plug connected to a cord. The cord may be connected to a back of the plug. A width of the plug may narrow from the back of the plug to a front of the plug. The cord may be connected to the back of the plug. The cord may include at least one electrical wire.