Universal Insulating Body for Plug Connectors
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Solution Overview
Problem
Existing plug connectors face challenges in assembly efficiency and cost due to the need for different insulating body shapes based on clamping devices, with preassembled clamping screws being difficult to assemble and additional parts required for security.
Innovation Solution
A universal insulating body design with a recess and flexible webs allows for secure clamping of both screwless and screw-based clamping elements, enabling detachable and reconnectable conductor attachment without additional parts, and facilitating preassembled assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the insulating body is designed with different shapes for different clamping devices, then the connector can accommodate various contact inserts, but the manufacturing complexity and inventory costs increase
Solution Approach 1:
The insulating body is designed with a universal receiving area that can accommodate both clamping screws and screwless clamping elements through a single standardized structure. The recess with flexible webs creates a multi-functional interface that adapts to different clamping device types without requiring different insulating body shapes, thus reducing the number of variants while maintaining compatibility.
Solution Approach 2:
The webs are designed with flexibility to dynamically adapt to different clamping device configurations. The flexible webs can deform to accommodate the specific geometry of either clamping screws or screwless clamping elements, allowing a single insulating body design to serve multiple functions that previously required different rigid structures.
2Reliability
If clamping screws are secured in the receiving area with additional insulating body parts, then the clamping screw is securely fixed, but the assembly complexity and production costs increase
Solution Approach 1:
The function of securing the clamping screw is merged into the insulating body itself through the recess structure with flexible webs. Instead of using separate additional insulating body parts or covers to secure the clamping screw, the recess integration provides both reception and securing functions in a single component, reducing part count while maintaining reliability.
Solution Approach 2:
The flexible webs provide self-service by automatically adapting and securing the clamping device without requiring additional fastening components. The elastic deformation of the webs creates a self-adjusting securing mechanism that holds both clamping screws and screwless clamping elements in place through the recess structure itself.
3Productivity
If the contact insert is preassembled with the clamping device, then assembly efficiency is improved, but the ability to attach conductors detachably is reduced
Solution Approach 1:
The connector is segmented into separable components: the contact insert with clamping device can be preassembled and inserted into the insulating body, while the conductor attachment remains a separate operation through the insertion opening. This segmentation allows efficient preassembly of the contact insert while preserving the ability to detachably attach conductors through the accessible insertion opening.
Solution Approach 2:
The insertion opening provides access to the conductor receptacle from a different dimension (through the insulating body), allowing conductor attachment to occur independently of the clamping device assembly. This dimensional access enables detachable conductor attachment even when the contact insert is preassembled with the clamping device.
Data Source
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Figure 3
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AI summary
The invention relates to a connector with a one-piece insulating body, which is designed with a receiving area for receiving a contact insert. The insert has, at a first end, a contact section for electrical connection with a correspondingly shaped contact piece of the connector, and at a second end, an insertion opening with a central longitudinal axis for receiving a conductor. A clamping device serves for the releasable and reconnectable fastening of the conductor to be received from a direction transverse to the central longitudinal axis. The clamping device comprises either a clamping screw or a screwless clamping element.A connecting section for the mechanical connection of the contact insert with the insulating body has at least one stop to cooperate with a locking element arranged on the connecting section for fastening the contact insert, and at least one recess in its receiving area, which is dimensioned so that both the clamping screw can be inserted into the recess and the screwless clamping element is accessible from the outside through the recess.