Connector Assembly Flex-Lock Feature for Terminal Retention
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Solution Overview
Problem
Existing electrical connector assemblies lack an effective locking mechanism to prevent accidental removal of electrical terminals, which can lead to disconnection and failure in applications like vehicle wiring harnesses.
Innovation Solution
The connector assembly incorporates a flex-lock feature with a planar-member and hinge mechanism that engages a locking-shelf and electrical terminals, providing a positive stop and resisting removal forces, while also distributing stress to prevent material failure and allowing multiple locking/unlocking cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing electrical connector assemblies are used without a locking mechanism, then the device complexity is reduced, but the reliability of electrical terminal retention deteriorates
Solution Approach 1:
The lock feature incorporates a movable planar-member that can transition between locked and unlocked positions, allowing the connector to dynamically adapt between secure retention and easy removal states. This dynamic element provides reliable terminal retention when locked while maintaining operational flexibility.
Solution Approach 2:
The lock feature is designed to be actuated by the user through simple manual operation, where the planar-member automatically engages with the locking-shelf to secure terminals. The system serves itself by using the user's removal force to both unlock and subsequently re-lock the terminals when reinserted.
2Reliability
If a locking mechanism is added to prevent accidental removal, then the reliability of electrical terminal retention is improved, but the ease of operation deteriorates
Solution Approach 1:
The planar-member is designed to be movable and flexible, allowing it to be easily actuated by the user during installation and removal operations. This dynamic characteristic ensures that while the locking mechanism provides secure retention, it does not significantly impede the ease of operation during intended installation/removal cycles.
3Strength
If a locking mechanism is implemented to resist removal forces, then the strength of terminal retention is improved, but the device complexity increases
Solution Approach 1:
The lock feature is integrated directly into the connector-body structure, merging the locking function with the existing connector housing. This integration approach provides strong resistance to removal forces while minimizing the increase in overall device complexity by avoiding separate locking components.
Solution Approach 2:
The locking-shelf acts as an intermediary element between the planar-member and the electrical terminals, providing a simple geometric interface that enables strong mechanical engagement without requiring complex locking mechanisms. The shelf translates the planar-member's movement into effective terminal retention.
4Reliability
If the lock feature is designed to engage firmly with the locking-shelf, then the reliability of terminal retention is improved, but the stress on the planar-member increases
Solution Approach 1:
The planar-member is designed with inherent flexibility and stress-distributing geometry that cushions the engagement with the locking-shelf. This design anticipates the stress that will occur during locking and provides a compliant structure that reduces peak stresses while maintaining reliable engagement.
Data Source
AI summary
A connector assembly includes a connector-body having electrical-terminals. The electrical-terminals are inserted into cavities defined by the connector-body through apertures defined in a rear-face of the connector-body. The connector-body includes a lock feature configured to releasably lock the electrical-terminals within the cavities. The lock feature has a planar-member with a first-end and a second-end. The first-end defines a flex-lock feature. The second-end is attached by a hinge to a leading-edge of the outer-surface of the connector-body proximate the front-face. The flex-lock feature defines a hook-side and a wall-side disposed within a slot defined by the connector-body. The hook-side is configured to releasably engage a locking-shelf partially enclosing the slot. The wall-side engages the electrical-terminals when the hook-side engages the locking-shelf. When a removal-force is applied to the electrical-terminals, the removal-force is transferred through the hook-side to the locking-shelf, thereby inhibiting removal of the electrical-terminals from the cavities.