Connector Assembly With Integrated CPA-TPA Terminal Locking
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Solution Overview
Problem
Existing electrical connectors lack an efficient mechanism for secure mechanical and electrical engagement, requiring separate connector position assurance (CPA) and terminal position assurance (TPA) elements, which complicates assembly and increases part management.
Innovation Solution
An improved terminal connector assembly with a CPA member that integrates a TPA function, allowing for synchronized activation and providing both primary and secondary locking mechanisms, eliminating the need for a separate TPA element and reducing assembly time and part complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate CPA and TPA elements are used in electrical connectors, then reliable mechanical and electrical engagement is achieved, but assembly complexity increases and assembly time is extended
Solution Approach 1:
The patent combines the CPA member and TPA element into a single integrated CPA member that performs both connector position assurance and terminal position assurance functions. The CPA member includes a TPA feature with a locking surface that engages the terminal locking latch, eliminating the need for a separate TPA element while maintaining reliable mechanical and electrical engagement.
Solution Approach 2:
The CPA member is designed to perform multiple functions: it provides connector position assurance by engaging the connector locking latch, and simultaneously provides terminal position assurance through its integrated TPA feature that engages the terminal locking latch. This multi-functional design reduces part count while ensuring reliable engagement.
2Reliability
If separate CPA and TPA elements are used, then distinct locking functions are provided, but assembly time and manufacturing complexity increase
Solution Approach 1:
The CPA member integrates both CPA and TPA functions into a single component that moves synchronously. When the CPA member is inserted, it simultaneously activates both the connector locking latch and terminal locking latch through its integrated features, reducing assembly steps and improving productivity while maintaining reliable locking functions.
Solution Approach 2:
The CPA member is pre-configured with both the CPA engagement surface and the TPA locking surface in fixed positions. During assembly, a single insertion action simultaneously performs both locking functions, eliminating the need for separate assembly steps and improving production speed.
3Reliability
If multiple separate elements are used for CPA and TPA, then comprehensive locking coverage is achieved, but part management and logistics become more difficult
Solution Approach 1:
The patent integrates the TPA element into the CPA member, creating a single component that provides both connector position assurance and terminal position assurance. This reduces the number of parts that need to be managed in logistics and inventory while maintaining comprehensive locking coverage through the integrated CPA and TPA features.
Data Source
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AI summary
A connector assembly comprising a connector (2) and a counter-connector, the connector (2) comprising a connector housing (6), at least one terminal (3), configured to be inserted in a cavity (7) formed in the connector housing (6), and a CPA member (5) slidably mounted onto the connector housing (6) between an initial position, an intermediate position and a final position, the movement of the CPA member (5) between the intermediate position and the final position being released by the mating of the connector (2) with the counter-connector. The CPA member (5) integrates a TPA element (24) configured to move with the CPA member (5) between a release position, in which the TPA element (24) allows said at least one terminal (3) to be fully inserted in its respective cavity (7), and a locking position, in which the TPA element (24) locks said at least one terminal (3) fully inserted in its respective cavity (7). Method for assembling such connector (2) and counter-connector.