Bulkhead Connector Assembly Independent Secondary Lock
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current bulkhead connector designs for automatic transmissions face challenges in sealing and terminal positioning, with existing seals being incompatible with automatic transmission fluids and lacking a reliable independent secondary lock for secure terminal retention, leading to potential leaks and assembly issues.
Innovation Solution
A bulkhead connector assembly featuring an outer housing with a sealing section and a terminal housing that includes primary locking mechanisms and an independent secondary lock (ISL) to ensure proper sealing and terminal retention, with the ISL movable between clearance and blocking positions to secure terminals and prevent extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If silicone seals are used to seal the terminal entry side, then sealing is provided, but the seals are incompatible with automatic transmission fluids and require fluid blocked wire
Solution Approach 1:
The patent changes the material parameter of the seal from silicone to a material compatible with automatic transmission fluids (such as fluorocarbon or polyacrylonitrile). This material substitution resolves the incompatibility issue while maintaining the sealing function, eliminating the need for fluid blocked wire.
2Reliability
If seals squeeze the outside of wire insulation to provide sealing, then sealing is achieved, but fluid blocked wire is required to prevent fluid wicking
Solution Approach 1:
The patent extracts the fluid blocking function from the wire structure by using a seal material that is inherently compatible with ATF. This eliminates the need for complex fluid blocked wire constructions, simplifying the overall assembly while maintaining sealing effectiveness.
3Manufacturing precision
If Terminal Position Assurance device is provided, then terminal positioning is assured, but the design is only Primary Latch Reinforcing and lacks Independent Secondary Lock
Solution Approach 1:
The patent segments the terminal retention function into two independent parts: a primary latch mechanism for initial positioning and an independent secondary lock for backup retention. This segmentation ensures that if the primary latch fails, the secondary lock maintains terminal security, enhancing overall reliability.
Solution Approach 2:
The independent secondary lock acts as a preemptive backup mechanism, providing cushioning against potential primary latch failure. This ensures terminal retention security is maintained even if the primary positioning mechanism fails.
4Reliability
If sealant is potted behind the TPA to seal terminals, then sealing is provided, but it is risk prone due to difficulty in assuring proper sealant dispensing
Solution Approach 1:
The patent employs a self-sealing mechanism where the connector housing itself provides the sealing function through integrated sealing structures, eliminating the need for manual sealant application. This self-service approach ensures consistent sealing quality without requiring complex dispensing processes or visual inspection of sealant placement.
Data Source
AI summary
A bulkhead connector assembly is provided having an outer housing that has an internal chamber. The outer housing has a sealing section configured to seal an exterior of the outer housing within an opening. A terminal housing is configured to hold a plurality of terminals. The terminal housing is received in the internal chamber. The terminal housing has primary locking mechanisms configured to secure the terminals in the terminal housing. An independent secondary lock (ISL) is separately provided from, and coupled to, the terminal housing. The ISL is configured to secure the terminals in the terminal housing and assure they are properly seated.