Vehicle Electrical Plug Receptacle Guide Contour

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Solution Overview

Problem

Existing electrical connector receptacles for vehicles face issues with secure and rapid contact establishment, as horizontal and vertical forces on contact elements can cause damage and buckling during plug insertion, and existing solutions often require soldering and additional components that increase assembly costs and risk of electrical shorts.

Innovation Solution

An electrical connector receptacle with a housing featuring a guide contour that allows precise vertical loading of contact elements, eliminating direct attachment and the need for soldering, and incorporating a metal die-casting process for enhanced strength and electromagnetic shielding, along with a sealing ring for protection and a securing element for secure connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If contact elements are used to guide the connector into the connector receptacle, then the connector can be inserted, but horizontal and vertical forces occur on the contact elements causing damage and buckling

Engineering Contradiction:

Improveconnector insertionVSAvoidcontact element integrity

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The guiding function is segmented from the contact elements and assigned to a dedicated guide contour structure on the housing. This separation allows the contact elements to focus solely on their electrical contact function while the guide contour handles the mechanical guidance and force absorption during insertion.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The guide contour acts as an intermediary structure between the connector and the contact elements. It mediates the insertion process by providing a dedicated path and absorbing insertion forces, preventing these forces from being transmitted directly to the contact elements.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If contact elements are fixed to the housing to divert forces, then the housing can absorb forces, but the contact elements still experience stress and require complex fixing mechanisms

Engineering Contradiction:

Improveforce absorptionVSAvoidcontact element fixation

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The force absorption function is extracted from the contact element-housing fixation system and assigned to the guide contour. This allows the contact elements to be fixed with simpler mechanisms since they no longer need to bear insertion forces.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of fixing contact elements to resist forces, the invention inverts the approach by providing a separate guiding structure that actively manages insertion forces before they can reach the contact elements.

Inventive Principle:

Principle #13The other way round (Inversion)

3Reliability

If soldering is used to attach contact elements to the circuit carrier, then electrical connection is established, but assembly costs increase and heating can damage sensitive circuits

Engineering Contradiction:

Improveelectrical connectionVSAvoidassembly process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention replaces the thermal-mechanical soldering process with a purely mechanical press-in contact system. Contact elements are mechanically pressed into receptacles on the circuit carrier, eliminating the need for heating equipment and solder material while maintaining reliable electrical connection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Object-affected harmful factors

If additional components for connector routing and contact shielding are used, then electromagnetic shielding and routing are improved, but component and assembly costs increase

Engineering Contradiction:

Improveelectromagnetic interferenceVSAvoidnumber of components

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The invention merges multiple functions into the guide contour structure: it provides mechanical guidance for the connector, structural support for the contact elements, and electromagnetic shielding. This consolidation eliminates the need for separate shielding components and simplifies the overall assembly.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP2915221B1Electrical plug receptacle for a vehicle

Publication Date: 2019.10.02 HELLA GMBH & CO KGAA

Figure 1~2
Figure 3

AI summary

The invention relates to an electrical plug receptacle (10) for a vehicle having at least one contact element (2), wherein the plug receptacle (10) has a housing (1) featuring an opening (12) and wherein a plug (16) featuring at least one contact element receptacle (14) can be led through the opening (12). According to the invention the housing (1) has a guide contour (4) for the plug (16), by which the plug (16) featuring the contact element receptacle (14) can be guided in the direction of the contact element (2) in order to produce an electrical contact.