Electrical Connector Dual-Function Flexible Beam Terminal Retention

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Solution Overview

Problem

Existing electrical connectors with flexible beams for terminal retention may not provide sufficient enhancement in retaining terminals within the connector body, as the force required to insert and lock terminals can be high due to simultaneous engagement with multiple ramps.

Innovation Solution

The electrical connector incorporates a dual-function flexible beam with a second rigid lock nib that engages terminals against a rigid wall and lock nibs, reducing the insertion force by sequential engagement with ramps and utilizing a pressure pad for enhanced retention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a flexible beam with a single lock nib is used to retain terminals, then terminal retention is provided, but terminal retention may be enhanced (insufficient retention force)

Engineering Contradiction:

Improveterminal retentionVSAvoidretention force

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The flexible beam is merged with a second rigid lock nib to create a dual-function component that combines the flexibility of the beam with the locking capability of the rigid nib, enhancing terminal retention without requiring separate components

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The flexible beam serves multiple functions: it provides initial terminal engagement, applies retention force through its flexibility, and incorporates a second rigid lock nib for enhanced locking, making it a multi-functional retention mechanism

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If multiple ramps are engaged simultaneously to lock terminals, then secure locking is achieved, but the force required for insertion becomes high

Engineering Contradiction:

Improvelocking securityVSAvoidinsertion force

Core Design Contradiction:

ReliabilityVSForce

Solution Approach 1:

The flexible beam engages the terminal preliminarily before the rigid lock nibs engage, gradually applying retention force and preparing the terminal for secure locking without requiring high insertion force

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The flexible beam provides dynamic engagement by gradually applying force as the terminal is inserted, allowing the retention force to increase progressively rather than requiring high force from the start

Inventive Principle:

Principle #15Dynamics

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

This design enhances terminal retention by reducing the force needed for insertion and locking, ensuring secure engagement of terminals within the connector body while allowing easy removal and broad applicability.

Implementation Method 1

The flexible beam engages the terminal in the cavity to hold the terminal against the rigid lock nib to retain the terminal in the terminal receiving cavity

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

The flexible beam has a second rigid lock nib to enhance terminal retention

Methodology Applied

Scientific EffectMechanical interlocking: Mechanical Fastener

Data Source

PatentUS7396255B2Electrical connector

Publication Date: 2008.07.08 APTIV TECHNOLOGIES AG

AI summary

An electrical connector has terminals that are retained in terminal cavities of a connector body by rigid lock nibs that project into the terminal cavity from a rigid wall and rigid lock nibs that are attached to a flexible beam that is opposite the rigid wall and that project into the terminal cavity.