Universal Insert Electrical Plug Subassembly Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The assembly of electrical plug type connectors from individual components is complex and time-consuming, requiring multiple steps and involving intricate positioning and securing mechanisms.
Innovation Solution
A subassembly comprising a housing with a universal insert and integral second contact securing members that prevent relative movement and ensure correct positioning, allowing for a single-step insertion and secure connection, with features like rib-like second contact securing members and snap-fit mechanisms for easy assembly and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate components (housing, contact securing members, positioning elements) are used to ensure stable connection and correct positioning, then connection reliability is improved, but assembly complexity increases and assembly time is extended
Solution Approach 1:
The patent combines multiple separate components into an integrated housing structure. The second contact securing member is formed as an integral part of the housing in one piece, and positioning elements are incorporated into the housing design. This merging reduces the number of separate parts while maintaining the stable connection and correct positioning functions, thereby simplifying assembly without compromising reliability
Solution Approach 2:
The housing is designed to perform multiple functions simultaneously: it provides structural support, contains the receiving chamber for the universal insert, forms the second contact securing member to prevent opening, and incorporates positioning elements for correct alignment. This multi-functionality reduces the need for separate dedicated components, simplifying the overall assembly while ensuring reliable connection
2Manufacturing precision
If multiple separate components with intricate positioning elements are used to ensure correct relative positioning, then positioning precision is improved, but assembly time is extended
Solution Approach 1:
The positioning elements and second contact securing member are pre-integrated into the housing structure during manufacturing. This preliminary action ensures that when assembly occurs, the positioning function is already built-in, eliminating the need for separate positioning steps during assembly and reducing assembly time while maintaining positioning precision
Solution Approach 2:
The housing combines positioning elements, securing functions, and structural support into a single integrated component. This merging eliminates multiple separate positioning and securing steps during assembly, reducing assembly time while ensuring correct relative positioning through the built-in design features
3Reliability
If multiple separate components are used for contact securing mechanisms, then connection reliability is improved, but production cost increases
Solution Approach 1:
The second contact securing member is formed as an integral part of the housing in one piece, eliminating the need for separate manufacturing and assembly of a dedicated securing component. This reduces part count, simplifies manufacturing processes, and lowers production costs while maintaining the reliability of contact securing through the built-in design
Solution Approach 2:
The housing serves as both the structural enclosure and the contact securing mechanism through its integral second contact securing member. This multi-functionality eliminates the need for separate securing components, reducing material costs, manufacturing complexity, and assembly operations while ensuring reliable contact securing
4Adaptability or versatility
If a universal insert with first contact securing member is used to secure contact elements, then adaptability is improved, but assembly complexity increases
Solution Approach 1:
The universal insert is designed to work with the integrated housing structure, providing adaptable contact element securing through the first contact securing member while the housing's second contact securing member and positioning elements provide additional functions. This universal design maintains versatility while the integration reduces overall assembly complexity by eliminating separate components
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a subassembly (10, 10A, 10B) for an electrical plug type connector (10', 10'A, 10'B) which can be connected to a mating connector (26) in an insertion direction (S). The invention further relates to a kit for producing at least two differently constructed electrical plug type connectors. In previous plug type connector systems, the assembly of an electrical plug type connector from its individual components is very complex and takes several steps. An object of the present invention is to provide a connector system in which the assembly is simplified over previous systems. The object is achieved by a subassembly (10, 10A, 10B) for an electrical plug type connector (10', 10'A, 10'B) comprising a housing (1, 1', 1'') and a universal insert (11) having a first contact securing member (16) which, in the secured state (G), prevents relative movement between the universal insert (11) and contact elements inserted into the universal insert, and wherein the housing (1, 1', 1'') has a receiving chamber (2) open at one end for the universal insert and a second contact securing member (5, 5A, 5B) which is formed on the housing (1, 1', 1'') in one piece and which blocks opening of the first contact securing member (16) when the universal insert (11) is correctly inserted into the receiving chamber (2). The universal insert (11) forms a kit for a connector system together with two differently constructed housings (1, 1', 1''), in which the universal insert (11) can be inserted.