Comb-Type Terminal Lock for Miniature Connector Assembly
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Solution Overview
Problem
Miniature coaxial connectors face challenges in assembly due to small secondary lock features, high production costs, and poor unseat detection feedback, particularly in connectors with multiple terminal rows, which are difficult to mold without increasing size or adding components.
Innovation Solution
An electrical connector design featuring a connector housing with flexible primary locking mechanisms and a comb-type secondary locking mechanism that includes members to engage terminal edges, preventing improper seating and allowing easy assembly, while the secondary locking mechanism moves to a staged position only when all terminals are properly seated, ensuring secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If miniature coaxial connectors are used to reduce size, then packaging efficiency is improved, but secondary lock features have small pushing surface areas making assembly difficult
Solution Approach 1:
The locking mechanism is divided into multiple comb-type members that can independently engage with terminals. This segmentation allows the locking function to be distributed across multiple smaller elements, maintaining effectiveness while adapting to the compact connector size.
Solution Approach 2:
The locking mechanism transitions from a traditional lateral locking approach to a comb-type structure that engages terminals in a different spatial arrangement. The comb members extend into terminal cavities and engage terminals from the side, providing adequate leverage and pushing surface area within the constrained miniature form factor.
2Adaptability or versatility
If multiple rows of terminals are included in miniature connectors, then connectivity options are improved, but molding becomes difficult without increasing size or adding components
Solution Approach 1:
The comb-type secondary locking mechanism serves multiple functions simultaneously: it locks multiple rows of terminals, provides unseat detection, and ensures proper seating of all terminals. This multi-functionality eliminates the need for separate CPA devices or additional secondary locks for each terminal row, simplifying the molding process.
Solution Approach 2:
The patent combines the secondary locking mechanism with unseat detection functionality into a single integrated structure. The comb-type members that provide locking also serve as the detection elements, eliminating the need for separate components and reducing molding complexity.
3Device complexity
If traditional locking mechanisms are used in miniature connectors, then structural simplicity is maintained, but unseat detection feedback is poor requiring additional components
Solution Approach 1:
The comb-type locking mechanism is designed to automatically provide unseat detection feedback through its own structure. When terminals are properly seated, the comb members can fully engage and the mechanism can transition to the locked position. If terminals are improperly seated, the comb members cannot engage properly, preventing the locking action and providing immediate tactile feedback to the assembler.
Solution Approach 2:
The mechanism incorporates inherent feedback through the engagement state of the comb-type members. The physical interaction between the comb members and terminal edges provides immediate feedback about proper seating, eliminating the need for separate detection systems or electronic monitoring.
Data Source
AI summary
An electrical connector includes a connector housing having terminal cavities which are arranged in an array having at least two rows and at least two columns. Each of the terminal cavities are configured to receive electrical terminals. Each terminal cavity defines a flexible primary locking mechanism integrally formed with the connector housing and configured to engage an edge of the electrical terminal, thereby inhibiting removal of the electrical terminals from the terminal cavities. The electrical connector also includes a secondary locking mechanism slidably attached to the connector housing and movable from a pre-staged position to a staged position. The secondary locking mechanism defines a plurality of members configured to extend into the terminal cavities and engage the edge of two electrical terminals when the secondary locking mechanism is in the staged position, thereby further inhibiting removal of the electrical terminals from the terminal cavities.