Connector Terminal Bias Tab for Lateral Positioning
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Solution Overview
Problem
Conventional electrical connector designs face challenges in maintaining tight lateral positional tolerances due to the use of flexible lock tabs and existing manufacturing processes, which result in excessive lateral positional tolerance, especially in miniaturized connectors.
Innovation Solution
The electrical connector assembly incorporates a conductive terminal with a rigid stop tab, a flexible lock tab, and a flexible bias tab that engage the connector body's inner walls to inhibit longitudinal and lateral movement, allowing for precise positioning without the need for additional locking features, thus mimicking tighter manufacturing tolerances while using existing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flexible lock tabs are used to retain terminals in connector cavities, then longitudinal locking is achieved, but lateral positional tolerance becomes excessive
Solution Approach 1:
The terminal is segmented into multiple functional tabs: a lock tab for longitudinal retention, a stop tab for longitudinal positioning, and a bias tab for lateral positioning. Each tab is independently configured to address specific positioning requirements, resolving the contradiction between longitudinal locking and lateral precision by dividing the retention function into specialized components.
Solution Approach 2:
The bias tab extends laterally from the terminal body to engage the cavity wall, introducing a lateral dimension of control that was previously absent. This lateral engagement mechanism operates perpendicular to the longitudinal locking direction, thereby constraining lateral positional tolerance without interfering with the longitudinal locking function.
2Volume of moving object
If connector size is reduced to lower cost and weight, then packaging and cost improve, but manufacturing tolerance control becomes more difficult
Solution Approach 1:
The bias tab automatically engages the cavity wall to urge the terminal into proper alignment, providing self-positioning that compensates for variations in manufacturing tolerances. This self-adjusting mechanism allows smaller connectors to maintain precise terminal positioning without requiring tighter manufacturing controls, thereby reducing cost while preserving precision.
Solution Approach 2:
The bias tab changes the mechanical parameter of terminal positioning by introducing a lateral urging force that actively maintains optimal terminal-cavity alignment. This dynamic parameter adjustment compensates for size reduction effects, allowing miniaturized connectors to achieve the same positioning precision as larger designs.
3Ease of manufacture
If existing manufacturing processes are used to control cost, then manufacturing cost is reduced, but lateral positional tolerance becomes excessive
Solution Approach 1:
The bias tab provides self-aligning functionality that compensates for tolerances introduced by conventional manufacturing processes. By automatically urging the terminal into proper lateral alignment through elastic engagement with the cavity wall, the design eliminates the need for expensive tight-tolerance manufacturing while maintaining precise terminal positioning.
Solution Approach 2:
The elastic properties of the bias tab allow it to accommodate manufacturing variations by adjusting its engagement force, thereby maintaining consistent terminal positioning across parts produced with conventional tolerances. This parameter flexibility enables cost-effective manufacturing without sacrificing precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design effectively reduces lateral positional tolerance, enabling more precise terminal placement and compatibility with smaller mating connectors, while maintaining comparable manufacturing costs and processes.
Implementation Method 1
a flexible bias tab having a fixed end attached to the body of the terminal and a free end extending outward laterally from the body of the terminal. The bias tab is configured to engage a second inner wall of the cavity and urge the body of the terminal into contact with a third inner wall of the cavity that is opposite the second inner wall
Implementation Method 2
The lock tab is configured to flex inwardly when contacting a first inner cavity wall of the cavity and configured to flex outwardly when the stop tab engages the first end of the connector body, thereby engaging the second end of the connector body
Data Source
AI summary
An electrical connector assembly having a connector body and a conductive terminal disposed within a cavity in the connector body. The terminal is held within the cavity by a rigid stop tab and a flexible lock tab that engage the ends of the connector body. A flexible bias tab having a fixed end attached to the body of the terminal and a free end extending outward laterally from the body of the terminal is configured to engage an inner wall of the cavity and urge the body of the terminal into contact with an opposite inner wall of the cavity, thereby inhibiting lateral movement of the terminal within the cavity. The bias tab may further limit rotational movement of the terminal within the cavity. The bias tab and/or any other feature of the terminal do not engage a locking feature located within the cavity.