Automotive Connector Holder Elastic Arm Biasing
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Solution Overview
Problem
Conventional connectors for automotive wire harnesses face issues with unstable terminal holding force and potential damage to elastic arms during terminal insertion, especially in high-current and high-voltage applications, due to dimensional errors and rigidity of electric wires.
Innovation Solution
A connector design featuring a terminal with a locking hole, a housing with a cavity and locking lances, and a holder with elastic arms that biases the terminal to hook onto the housing lance, preventing shifting and damage during insertion, and utilizing a holder locking mechanism to secure the terminal in a stable position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the terminal cavity dimension is set slightly larger than the terminal thickness to accommodate dimensional errors and insertion variations, then the insertion property is improved, but the terminal may move away from the housing lance and lock at a distal end portion with small shear area, reducing the locking force
Solution Approach 1:
The patent introduces a holder as an intermediary component between the terminal and housing. The holder elastic arm acts as a mediator that applies biasing force to guide the terminal into proper engagement with the housing lance, preventing the terminal from shifting to positions with insufficient locking force while maintaining ease of insertion.
Solution Approach 2:
The patent changes the mechanical parameters by introducing elastic biasing force through the holder elastic arm. This elastic force dynamically adjusts the terminal position during insertion, ensuring the terminal engages with the housing lance at the optimal position with sufficient shear area, rather than allowing free movement to distal end portions.
2Reliability
If the housing elastic arms protrude into the terminal cavity to bias the terminal, then the terminal holding force is improved, but the elastic arms may be damaged by prying forces during terminal insertion
Solution Approach 1:
The holder is pre-installed on the housing before terminal insertion. The holder elastic arm is pre-positioned to provide biasing force, but the actual engagement and locking action occurs after the terminal is inserted, separating the functions of guidance and locking to prevent damage during insertion.
Solution Approach 2:
The patent segments the functions of terminal guidance and locking into separate components: the holder elastic arm provides biasing and guidance, while the housing lance provides the final locking engagement. This segmentation protects the elastic arm from experiencing excessive prying forces that would occur if it directly engaged the terminal during insertion.
3Power
If the connector is designed for high-current and high-voltage applications with thick electric wires, then the power transmission capability is improved, but the wire rigidity causes large tensile loads during bending, requiring increased shear area or rigidity of the housing lance
Solution Approach 1:
The holder acts as an intermediary that absorbs and distributes the tensile loads generated by rigid thick wires during bending. The holder elastic arm provides continuous biasing force that compensates for wire movement, reducing the direct tensile load on the housing lance and preventing damage without requiring increased shear area or rigidity.
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 connector achieves a continuously stable terminal holding force without damaging the holder elastic arms during insertion, improving operational stability and workability, and preventing deformation of housing components under tensile loads.
Implementation Method 1
a holder elastic arm for biasing the terminal in a direction of hooking the terminal to the housing lance
Data Source
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AI summary
A connector includes: a terminal (2) having a terminal locking hole (3); a housing (10) including a terminal cavity (11) into which the terminal (2) is inserted, and a housing lance (12) configured to be locked with the terminal locking hole (3) of the terminal (2) inserted into the terminal cavity (11); and a holder (20) configured to be fitted to the housing (10) and having a holder elastic arm (23) for biasing the terminal (2) in a direction of hooking the terminal (2) to the housing lance (12).