Electrical Connector Cam Actuated Terminal Lock
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Solution Overview
Problem
Electrical connectors face challenges in accommodating terminals of varying sizes, requiring different terminal position assurance (TPA) device designs that operate in multiple directions, which complicates packaging and increases size.
Innovation Solution
An electrical connector design that integrates both axial and vertical TPA devices within a single housing, utilizing a cam-driven mechanism to actuate the vertical TPA, allowing for simultaneous operation of both devices in a single motion, thereby maintaining a compact package size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If different TPA device designs are used for terminals of varying sizes, then terminal positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The patent applies universality by designing a single TPA device structure that can accommodate terminals of varying sizes through adjustable positioning elements. The TPA device includes positioning tabs that can be selectively engaged with different terminal types, allowing one device design to serve multiple terminal size categories rather than requiring separate dedicated devices for each terminal type.
Solution Approach 2:
The TPA device is segmented into modular components including positioning tabs, locking elements, and adjustable arms. Each segment can be independently configured to match specific terminal dimensions, enabling the same TPA device structure to adapt to various terminal sizes through reconfiguration of its segmented parts rather than requiring entirely different device designs.
2Adaptability or versatility
If TPA devices operate in two different directions, then adaptability to various terminal designs is improved, but packaging space increases
Solution Approach 1:
The TPA device employs dynamic elements that can change operational direction based on terminal requirements. The positioning arms and locking mechanisms are designed to pivot or rotate between axial and vertical orientations, allowing the same physical device to operate in multiple directions dynamically rather than requiring separate static devices for each direction, thus maintaining compact packaging.
Solution Approach 2:
The patent utilizes dimensional transformation by designing the TPA device to transition between operating in the axial dimension and the vertical dimension. The mechanism includes movable components that can shift their operational plane, enabling the device to engage terminals either axially or vertically as needed, effectively packing multi-directional functionality into a single compact structure without increasing overall connector footprint.
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
The solution effectively inhibits axial movement of electrical terminals while allowing for secure locking and insertion, accommodating terminals of varying dimensions without increasing the connector's size, ensuring efficient and compact terminal positioning.
Implementation Method 1
The terminal lock moves from the terminal insertion position to the locking position as the slidable skirt is moved from the pre-stage position to the seated position by the assembler as the cam posts travel in the cam slots
Data Source
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AI summary
An electrical connector (10) includes a first-housing (12), a second-housing (16), a slideable-skirt (34), and a terminal-lock (48). The second-housing (16) is configured to mate with the first-housing (12) along a longitudinal-mating-axis (18). The second-housing (16) defines a slot (28) in a top-side (30) of the second-housing (16) extending along a lateral-axis (32) orthogonal to the longitudinal-mating-axis (18). The slideable-skirt (34) is mounted to the second-housing (16) and is moveable from a pre-stage position (36) to a seated-position (38) along the longitudinal-mating-axis (18). The slideable-skirt (34) overlays a portion of a perimeter of the second-housing (16) and defines cam-slots (40) on a first-side (42) and a second-side (44) of the slideable-skirt (34). The terminal-lock (48) is disposed within the slot (28) and is moveable from a terminal insertion position (50) to a locking position (52). The terminal-lock (48) includes cam-posts (58) extending from a first-end (60) and a second-end (62) of the terminal-lock (48) disposed within the cam-slots (40). The terminal-lock (48) moves from the terminal insertion position (50) to the locking position (52) as the slideable-skirt (34) is moved from the pre-stage position (36) to the seated-position (38).