Electrical Connector CPA Layout for Uniform Locking Force
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connectors in the automobile industry face challenges with non-uniform force distribution and potential short circuits due to helical compression springs, which hinder size reduction and compatibility with compact squib connectors used in safety restraint systems.
Innovation Solution
An electrical connector design featuring a conductive terminal, housing, compressive member, and connector position assurance (CPA) element, where the CPA's flat head aligns with the plug-in portion's central axis, ensuring uniform force distribution and preventing short circuits, allowing for a more compact and stable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a helical compression spring is used in the connector, then the compressive force can be generated to eject mismatched connectors, but the force distribution becomes non-uniform and the connector size increases
Solution Approach 1:
The patent extracts the helical compression spring from the connector design and replaces it with a compressive member that has a flat head bearing surface. This removal of the problematic spring component eliminates the non-uniform force distribution and space requirements while maintaining the necessary compressive force generation capability through alternative means.
Solution Approach 2:
The patent introduces a flat head bearing surface at the specific location where force is applied to the CPA element. This localized flat surface ensures uniform force distribution at the critical interface, while the overall connector design can be optimized for compactness in other areas, resolving the contradiction between force quality and size.
2Force
If a helical compression spring is used, then compressive force can be sustained, but the risk of involuntary contact with conductive terminals increases causing short circuits
Solution Approach 1:
The patent removes the helical compression spring from the system, eliminating the source of involuntary contact with conductive terminals. The compressive force function is retained through a redesigned compressive member with a flat head that contacts the CPA element in a controlled manner, preventing harmful interactions with electrical components.
Solution Approach 2:
The flat head bearing surface acts as an intermediary between the compressive member and the CPA element. This intermediate flat surface provides a controlled, non-conductive contact point that transmits compressive force without risking contact with conductive terminals, thereby preventing short circuits while maintaining force transmission.
3Volume of moving object
If the connector is designed for compactness to meet squib connector standards, then the dimensions are reduced, but the space for locking spring travel becomes insufficient
Solution Approach 1:
The patent extracts the traditional helical compression spring mechanism that required significant axial travel space. By replacing it with a compressive member having a flat head that acts directly on the CPA element, the design eliminates the need for extensive spring travel space, enabling compact connector dimensions while maintaining locking functionality.
Solution Approach 2:
The patent transitions from a spring mechanism requiring axial dimension for travel to a flat head bearing surface that operates with minimal axial displacement. This dimensional change allows the locking action to occur within a compact space envelope, meeting squib connector size requirements while preserving ease of operation.
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 design achieves uniform force distribution, prevents short circuits, and enables a more compact and reliable electrical connector, suitable for compact applications like squib connectors in motor vehicles, while using larger compressive members for equivalent force.
Implementation Method 1
a compressive member (18) arranged within the housing and compressed along the mating direction
Implementation Method 2
a connector position assurance element (16) slidable from an unlocked position to a locked position along the mating direction
Data Source
AI summary
An electrical connector for connecting with a mating electrical connector in a mating direction includes an electrically conductive terminal having an electrical contact, a housing having a plug-in portion insertable into the mating electrical connector along the mating direction, the plug-in portion having a receptacle receiving the electrical contact, a compressive member arranged within the housing and compressed along the mating direction, and a connector position assurance element (CPA) slidable from an unlocked position to a locked position along the mating direction. The locked position allows the electrical connector to be locked to the mating connector when the electrical connector is connected to the mating connector. A central axis of the compressive member is aligned with a central axis of the plug-in portion in the mating direction.