Connector Debris Shield and CPA Engagement Mechanism
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Solution Overview
Problem
Existing electrical connectors in vehicle engine compartments and passenger compartments face issues with debris accumulation during assembly processes, such as painting, which can render the Connector Position Assurance (CPA) device permanently locked, requiring costly solutions like rubber boots or labor-intensive masking tape to prevent damage, and these methods are not always effective.
Innovation Solution
A protection device with a deflector element and a CPA assist is designed to shield the CPA and CPA slot from debris, allowing the CPA to remain serviceable and dis-connectable after assembly processes, featuring a deflector element with a receiving slot and a CPA assist that can be engaged to ensure proper CPA activation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the CPA is inserted into the CPA slot during assembly, then connector engagement can be verified, but the CPA becomes permanently locked by paint or debris requiring wire cutting for disconnection
Solution Approach 1:
The patent applies preliminary action by pre-staging the CPA in a removable state before the painting process, then engaging it after painting is complete. This sequence ensures the CPA can be properly verified while avoiding permanent locking from paint exposure during the critical engagement phase.
Solution Approach 2:
The patent segments the CPA protection into distinct phases: a protective cover shields the CPA slot during painting, while the CPA itself remains separate and can be engaged afterward. This segmentation allows the verification function to be maintained while preventing the harmful effect of paint exposure.
2Ease of repair
If rubber boots or masking tape are used to protect the CPA from paint, then the CPA remains serviceable, but the solution becomes costly or labor-intensive
Solution Approach 1:
The patent merges the protective function with the connector assembly structure itself. The protective cover is integrated into the connector design, combining protection and structural functions into a single unified component rather than adding separate protective elements like rubber boots or masking tape.
Solution Approach 2:
The protective cover is designed to be self-contained and automatically provides protection without requiring external masking materials or additional protective components. The structure itself serves the protective function, eliminating the need for separate protection methods.
3Reliability
If the CPA is engaged before painting, then connector position assurance is established, but paint seals the CPA in place rendering it permanently locked
Solution Approach 1:
The patent reverses the traditional sequence by delaying CPA engagement until after painting is complete. The protective cover remains in place during painting to shield the slot, then the CPA is engaged in the clean post-painting environment, ensuring both protection from paint and proper verification.
Solution Approach 2:
The protective cover serves as an intermediary element between the painting process and the CPA slot. It allows the painting operation to proceed while preventing paint contact with the CPA, then is removed to allow clean engagement of the CPA for verification.
Data Source
AI summary
A device has both a debris deflector and a built in CPA assist. The debris deflector is a (sufficiently) large shield that covers the CPA slot and the CPA in the pre-staged arrangement. The device further includes a CPA assist that is configured to engage the pre-staged CPA (now covered by the debris deflector) so that it can allow the manufacturer to engage the now protected CPA when desired.