Terminal positioning device
The terminal positioning device addresses assembly errors in electrical connectors by ensuring proper terminal alignment and locking, reducing complexity and manufacturing costs while improving connector reliability.
Patent Information
- Application Number
- JP2024094172
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-06-12
- Filing Date
- 2024-06-11
- Publication Date
- 2024-12-24
AI Technical Summary
Electrical connectors face assembly errors due to incorrect or insufficient terminal insertion, leading to increased manufacturing costs, complexity, and suboptimal terminal positioning, despite the use of terminal position assurance (TPA) devices.
A terminal positioning device with a movable sliding surface and terminal locks that ensure proper terminal alignment and locking within the connector, minimizing space occupation and reducing manufacturing complexity.
The device optimally positions terminals, reducing assembly errors and maintaining stability under vibration or shock conditions, enhancing connector performance and reliability.
Smart Images
Figure 2024178138000001_ABST
Abstract
Description
[Technical field]
[0001] The present invention relates to connectors, and more particularly to terminal positioning devices and associated connectors. [Background technology]
[0002] Electrical connector systems are often subject to assembly errors. These errors include, for example, incorrect or insufficient insertion of the connector's terminals within their corresponding housings. As a result, electrical connectors often implement terminal position assurance (TPA) devices or components that reliably detect partially seated terminals during assembly or mating of the connector system. This allows operators to identify and remedy terminal placement issues during the connector assembly process or connector mating process to avoid connector damage and / or failed or unreliable connections.
[0003] Given these benefits, there is an increasing demand for connectors that utilize TPA components. However, their implementation is not without drawbacks. For example, the presence of TPA devices increases manufacturing and assembly costs and overall connector complexity. Additionally, these components often occupy a large amount of space within the connector. Furthermore, they often do not ensure optimal positioning of the terminals. Summary of the Invention [Problem to be solved by the invention]
[0004] Therefore, there is a need for an improved system and method for ensuring proper installation of terminals in an electrical connector. [Means for solving the problem]
[0005] In one embodiment of the disclosure, an electrical connector includes a terminal holder and a terminal positioning device. The terminal holder defines at least one terminal opening configured to receive a terminal from a first side thereof in a terminal insertion direction. The terminal positioning device includes a sliding surface that abuts a portion of the connector and at least one terminal contact surface. The terminal positioning device is disposed adjacent to the first side of the terminal holder and is movable relative to the terminal holder in a movement direction perpendicular to the insertion direction between a first position in which the terminal positioning device does not overlap the at least one terminal opening in the insertion direction and a second position in which the at least one terminal contact surface overlaps the at least one terminal opening in the insertion direction.
[0006] The invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]
[0007] [Figure 1] 1 is a partial cross-sectional side view of an electrical terminal including a terminal positioning device in an open position and a terminal in a partially inserted position according to one embodiment of the present disclosure. [Diagram 2] 2 is another cross-sectional side view of the connector of FIG. 1 with the terminal positioning device in a closed position and the terminals in a partially inserted position. [Diagram 3] 3 is another cross-sectional side view of the connector of FIG. 2 with the terminals in a fully inserted or installed position. [Figure 4] FIG. 1 is a front perspective view of a terminal positioning device according to one embodiment of the present disclosure. [Diagram 5] 5 is a detailed view of a portion of the terminal positioning device of FIG. 4. [Figure 6] 4 is a cross-sectional view of the electrical connector of FIGS. 1-3 with the terminal positioning device in an open position. FIG. [Figure 7] 7 is a cross-sectional view of the electrical connector of FIG. 6 with the terminal positioning device in a closed position. [Figure 8] 4 is a cross-sectional rear view of the electrical connector of FIGS. 1-3, with the terminal positioning device in an open position. FIG. [Figure 9] 9 is a cross-sectional rear view of the electrical connector of FIG. 8 with the terminal positioning device in a closed position. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0008] Exemplary embodiments of the present disclosure are described in detail below with reference to the accompanying drawings, in which like reference numerals refer to like elements. However, the present disclosure may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of the disclosure to those skilled in the art.
[0009] In the following detailed description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. However, it will be apparent that one or more embodiments may be practiced without these specific details. In other instances, well-known structures and devices are shown in schematic form to simplify the drawings.
[0010] An embodiment of the present disclosure includes a terminal positioning device configured to position and lock a terminal within an electrical connector. In one embodiment, an electrical connector is provided that includes a terminal holder defining at least one terminal opening, at least one terminal positioned in an insertion direction from a first side of the terminal holder into at least one of the openings, and a terminal positioning device disposed adjacent the first side of the terminal holder. The terminal positioning device is movable relative to the terminal holder in a direction of movement perpendicular to the direction of insertion of the terminal. The terminal positioning device includes a body having a terminal locking protrusion extending from the body in a direction toward the terminal. The terminal locking protrusion defines a ramp extending obliquely relative to the direction of movement of the device. The device is movable between a first initial position in which the terminal locking projections are operatively offset from the terminals and a second position in which the terminal locking projections are at least partially operatively aligned with the terminals.
[0011] 1-3 generally, embodiments of the present disclosure will be described as implemented in an exemplary electrical connector 10. The representative connector 10 includes a body 12 (e.g., a molded polymeric body) defining a receiving cavity or opening 14 through which, for example, a mating connector can be inserted in a mating direction M. The body 12 houses one or more conductive terminals 20, a terminal holder 30, an optional pin protection device 40, and a terminal positioning device 100 according to one embodiment of the present disclosure. In the exemplary connector 10, the terminals 20 are rear-loaded or installed in an insertion direction I into the rear of the terminal holder 30.
[0012] Each terminal 20 includes a mating end 21 (e.g., a pin) and a connecting end 22 (e.g., a crimp as shown in FIGS. 6 and 7). Each terminal 20 further defines a locking element or mechanism 24. The locking element 24 of the exemplary terminal 20 extends from a top surface thereof and is sized and positioned to engage a corresponding locking mechanism of the connector 10. More specifically, the terminal holder 30 is fixedly disposed within the cavity 14 of the connector 10 and includes a plurality of openings 32, each sized to receive one of the terminals 20. The terminal holder 30 defines a primary terminal lock 34, such as a cantilevered locking arm extending into each opening 32. Each terminal lock 34 is operative to engage the locking element 24 of each terminal 20 after the terminal is fully inserted to a predetermined depth within the terminal holder 30. When engaged, terminal lock 34 prevents removal of terminal 20 from terminal opening 32 in a direction opposite insertion direction I.
[0013] 1 and 2, terminal 20 is only partially installed or inserted into terminal holder 30. As a result, terminal lock 34 is not engaged with locking element 24 of terminal 20. In this position, terminal 20 may be shifted further rearward (e.g., during mating) or even completely disengaged from terminal holder 30. Additionally, the partially installed terminal 20 shown in FIGS. 1 and 2 does not provide the same wipe or conductive contact area as the mating connector.
[0014] However, as shown in Fig. 3, after the terminal 20 is inserted into the opening 32 deep enough to pass through the terminal lock 34, the lock resiliently deflects vertically downwards and faces the terminal's locking element 24 in a direction opposite to the insertion direction I. In this state, while the terminal 20 is prevented from disengaging from the terminal holder 30, the terminal 20 is not necessarily maintained in this optimal position (i.e., its forward-most position). Specifically, as can be seen in Fig. 3, a gap 33 exists between the terminal lock 34 and the locking element 24. As a result, the terminal 20 can be shifted backwards (e.g., during mating) until such gap is eliminated while still being locked in the terminal holder 30. A terminal positioning device 100 according to an embodiment of the present disclosure operates to prevent the partial terminal insertion condition shown in FIGS. 1 and 2, to optimally position each terminal within its terminal holder, and to maintain such position during use as shown in FIG.
[0015] An exemplary configuration of a terminal positioning device 100 is shown in Figures 4 and 5. The terminal positioning device 100 includes a frame having a generally horizontal top wall 102, a generally horizontal bottom wall 104, and two vertical side walls 106. In some embodiments, an intermediate support 108 is provided and spans between the side walls 106 at a non-zero vertical distance from the top and bottom walls 102, 104. As a result, two slots or openings 110 are defined on either side of the intermediate support 108. The openings 110 are configured (i.e., sized and positioned) to receive therethrough a portion of the terminal 20 extending rearwardly from the insertion side or rear of the terminal holder 30, as shown, for example, in Figures 1-3.
[0016] The terminal positioning device 100 further includes at least one terminal lock protrusion or terminal lock 150. In the exemplary embodiment, the device 100 defines two rows of a plurality of terminal locks 150 with each lock evenly spaced along the row. The spacing of the terminal locks 150 corresponds to the spacing of each terminal 20 of the connector 10. In the exemplary embodiment, each terminal lock 150 includes a tooth-like projection or tooth-like projection 152 extending from each of the top and bottom walls 102, 104, and a terminal contact surface including a sloped surface or portion 154 and a planar bearing surface or portion or planar locking surface or portion 156. See, for example, FIG. 5, where the protrusion 152 of the terminal lock 150 extends vertically downward from the top wall 102. A sloped surface or inclined portion 154 extends from the protrusion 152 in a direction away from the top wall 102. Specifically, the sloped surface 154 extends obliquely relative to a sliding or support surface of the device 100 (e.g., the back surface 101 and / or the flat surface 154 of the device 100). The direction of the slope is opposite to the operating direction O of the device 100. A flat support portion 156 of the contact surface is formed directly adjacent to the sloped portion 154. The flat support portion 156 may be generally parallel to the front surface 101′ and / or the back surface 101 of the device 100 and / or the rear surface 36 of the terminal holder 30, and serves as a support surface for the terminal holder 30 when the device 100 moves in the operating direction O. See FIGS. 6 and 7. Additionally, the planar surface or planar portion 156 acts as a mechanical stop in the closed position of the device 100, preventing movement of the terminals in a direction opposite the insertion direction I. See Figures 3, 7 and 9.
[0017] 4 and 5, the device 100 includes a pair of detents or latching protrusions 114. In the exemplary embodiment, one detent 114 is formed in each of the top wall 102 and the bottom wall 104. A void space or opening 118 is formed directly below (or directly above) each detent 114, forming a spring-like beam on which the detents 114 are formed. This causes each detent 114 to resiliently move in the direction of the opening 118, for example when subjected to a compressive force. As will be described in more detail with respect to FIGS. 8 and 9, the detents 114 are used to control the position of the device 100 in use. Terminal positioning device 100 further includes at least one, and in the illustrated embodiment two, actuators 120 extending in a forward direction from its surface 101'. As can be seen in Figure 1, actuators 120 extend through cavity 14 of connector 10 and provide a means for a user to mechanically bias device 100 in operating direction O (or in the reverse direction).
[0018] The function of the terminal positioning device 100 will now be described with reference to Figures 2 and 3. Figure 2 provides an illustration of the terminal 20 in a partially inserted or partially installed position and the device 100 in a locked or closed position, showing the interference that exists between the terminal lock 150 and the rear face 26 of the terminal 20. Figure 3 illustrates the terminal 20 in a fully inserted position. As shown, the flat 156 of the terminal lock 150 abuts the rear face 26 of the terminal 20. The front portion 27 of the terminal abuts against the opposing end face 35 of the terminal holder 30. This places the terminal 20 in its forward most or ideal position. As a result, the constant insertion force applied by the device 100 maximizes terminal wipe and minimizes motion (e.g., due to vibration).
[0019] The device 100 is shown in a first or open position in FIG. 6. In this position, the terminals 20 are freely inserted or seated in the terminal holder 30 at least partially through the gaps formed between adjacent terminal locks 150 during assembly of the connector 10. As shown, each terminal 20 is only partially seated or inserted in its respective opening 32. The terminal positioning device 100 is slidable from the open position shown in FIG. 6 in the indicated operating direction O. Specifically, the device 100 is slidably held between the rear face 36 of the terminal holder 30 and the opposing interior wall or surface 15 of the connector body 12. As the device 100 is biased in the direction O, each terminal lock 150, with the angled surface 154 leading, engages the rear end face 26 of each terminal 20. As device 100 is further urged in direction O, terminals 20 are forced in insertion direction I via angled surfaces 154. Figure 7 illustrates a second, or closed, position of device 100 in which rear face 26 of each terminal 20 reaches abutment with flats 156 of each terminal lock 150. Terminals 20 have reached, or nearly reached, their final, fully seated position and continue to be held there by continued engagement with device 100.
[0020] 8 is a rear cross-sectional view of the device 100 in a first or open position. The ends of the terminals 20 extend through the openings 110 of the device 100 without being impeded by the terminal locks 150 being offset from the terminals in the operating direction O (or vice versa). The detents 114 of the device 100 abut against similar protruding elements 18 of the connector body 12, thus providing a positive stop for the user to identify the open position. This may also be considered the loaded position of the device 100, where the terminals 20 are free to sit in the connector body 12 / terminal holder 30 without interference. By biasing the device 100 in the operating direction O, the detents 114 are compressed and pass their corresponding protruding elements 18 as the device moves to the closed position shown in FIG. During this operation, any terminals 20 that are not fully seated are pushed or moved closer to the fully seated position, as described above. The resistance provided by the engagement of the detents 114 with the element 18 provides a mechanical feel to the user. More specifically, an indication is provided that the device 100 has been moved from the open position to the closed position, and therefore no further force needs to be applied to the device. Of course, additional detents or mechanical stops may be further provided to limit the movement of the device 100 to prevent the user from biasing the device 100 beyond the closed position. For example, as shown in FIG. 9, the side wall 106 of the device 100 may abut against an opposing inner wall of the connector body 12. The device 100 may remain in this second, locked, or closed position, thereby ensuring that the position of the terminals 20 remains optimized, improving the performance of the connector, particularly in high vibration or high shock applications.
[0021] Although embodiments of the present disclosure are described in the context of an exemplary electrical connector 10 including a terminal holder 30, the embodiments may be used with connectors having other configurations and / or other features, including connectors that do not have a separate terminal holder, without departing from the scope of the present disclosure.
Claims
1. A terminal positioning device (100) for an electrical connector (10), comprising: - a sliding surface (101) adapted to slide in an operating direction (O) relative to a component of said electrical connector (10); at least one beveled surface (154) obliquely oriented with respect to said sliding surface (101) and configured to selectively engage an electrical terminal (20) of said electrical connector (10); - an opening (110) sized and positioned to receive a portion of said electrical terminal (20) therethrough; Equipped with A terminal positioning device (100).
2. a plurality of terminal locks (150) extending from said device (100) in a direction generally perpendicular to said direction of movement; Each of the terminal locks (34) defines a terminal contact surface (154, 156) that includes the beveled surface (154). The device (100) of claim 1.
3. The terminal contact surface (154, 156) further includes a planar portion (156) adjacent the beveled surface (154); The device (100) of claim 2, wherein the planar portion (156) defines a contact surface parallel to the sliding surface (101).
4. The plurality of terminal locks (150) are arranged in a row extending in the operating direction (O). The device (100) of claim 2.
5. the plurality of terminal locks (150) are arranged in a plurality of rows, each row extending in the movement direction (O) and spaced apart from adjacent rows in a direction perpendicular to the movement direction; The device (100) of claim 4.
6. further comprising a top wall (102), a bottom wall (104), and at least one wall (106) connecting said top wall to said bottom wall; The device (100) of claim 4.
7. The array of terminal locks (150) extends from the top wall (102) or the bottom wall (104). The device (100) of claim 6.
8. Further comprising an actuator (120) extending in a direction perpendicular to the movement direction (O). The device (100) of claim 1.
9. a mechanical stop (114) defined on an outer surface of the device (100) and configured to interface with the electrical connector (10) to limit the range of movement of the device in the operating direction (O). The device (100) of claim 1.
10. An electrical connector (10), comprising: The electrical connector (10) comprises: - a terminal holder (30) defining at least one terminal opening (32) configured to receive a terminal (20) from a first side of the terminal holder in a terminal insertion direction (I); a terminal positioning device (100) disposed adjacent to the first side of the terminal holder (30); The terminal positioning device (100) comprises: A sliding surface (101) that abuts against a portion of the connector; at least one terminal contact surface (154, 156); The terminal positioning device (100) comprises: a first position in which the device (100) does not overlap the at least one terminal opening (32) in the insertion direction; between a second position in which the at least one terminal contact surface (154, 156) overlaps the at least one terminal opening (32) in the insertion direction (I); The terminal holder (30) is movable in an operating direction (O) perpendicular to the insertion direction (I). An electrical connector (10).
11. a connector body (12) defining a cavity (14); the terminal holder (30) is disposed within the cavity (14), and the terminal positioning device (100) is disposed between the first side of the terminal holder (30) and an inner wall (15) of the connector body (12); The sliding surface (101) of the device (100) abuts against the inner wall (15); The electrical connector (10) of claim 10.
12. The at least one terminal contact surface (154, 156) is a sloped surface (154) oriented obliquely with respect to said sliding surface (101); a flat portion (156) that is parallel to the sliding surface (101) and adjacent to the inclined surface (154), the flat portion (156) abutting against the first side surface of the terminal holder (30); The electrical connector (10) of claim 10.
13. The terminal positioning device (100) includes a plurality of terminal locks (150) extending in a direction perpendicular to the direction of motion (O), each of the terminal locks (150) defining a terminal contact surface including the inclined surface (154) and the planar portion (156). The electrical connector (10) of claim 12.
14. The plurality of terminal locks (150) are arranged in a row extending in the operating direction (O). The electrical connector (10) of claim 13.
15. and at least one terminal (20) disposed within the at least one terminal opening (32) of the terminal holder (30); the at least one terminal contact surface (154, 156) abuts the at least one terminal (20) in the insertion direction (I) in the second position of the terminal positioning device (100); The electrical connector (10) of claim 10.