Two-Stage Connector Housing With Resilient Lance For Low Insertion Force
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Solution Overview
Problem
Existing connectors require high inserting force for female terminals, leading to potential defects and lack consideration for chattering and releasing forces when separate housings are fitted, particularly in directions parallel to the groove and during lock mechanism operation.
Innovation Solution
The connector design includes a two-stage fitting mechanism with a resilient lance for reduced inserting force, L-shaped engagement features for chattering prevention, and guide ribs and grooves for reduced fitting and releasing forces, allowing for sliding contact and secure locking with minimal deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the female terminal is inserted while bending the contact member and deforming the lance, then the female terminal is secured in the terminal receiving cavity, but the inserting force becomes excessively large
Solution Approach 1:
The patent divides the fitting process into two distinct stages: first the housing engagement (first fitting position) where the lance engages the locking hole, and second the terminal engagement (second fitting position) where the male terminal contacts the female terminal. This segmentation allows the lance deformation to occur in stages, reducing the peak force required compared to simultaneous engagement.
Solution Approach 2:
The patent performs preliminary engagement of the housing at the first fitting position before completing the terminal insertion. The lance is preliminarily engaged with the locking hole while the housing is fitted, preparing the structure for the subsequent terminal contact without requiring full insertion force upfront.
2Ease of manufacture
If the female terminal housing and male terminal housing are separately formed, then the connector allows modular assembly, but chattering occurs during fitting due to manufacturing tolerances
Solution Approach 1:
The patent introduces L-shaped engagement features that extend in multiple directions (both perpendicular and parallel to the wall surface). This multi-dimensional engagement prevents chattering by constraining movement in all relevant directions, not just the primary fitting direction.
Solution Approach 2:
The L-shaped engagement features have asymmetric geometry with different dimensions in different directions. This asymmetry allows the features to engage in a specific orientation that prevents chattering while accommodating manufacturing tolerances, providing directional stability during fitting.
3Reliability
If a locking hook and locking concave portion are used to lock the housings, then the fitted state is secured, but the releasing force becomes excessively large
Solution Approach 1:
The patent uses resilient (elastic) engagement features including the lance and L-shaped features that can dynamically deform during engagement and release. These features flex during fitting and then elastically recover to maintain the locked state, allowing easy release without excessive force compared to rigid locking mechanisms.
Solution Approach 2:
The resilient engagement features change their physical state (deformed vs. recovered) during engagement and release. The lance and L-shaped features deform during fitting to accommodate the connection, then elastic recovery maintains the locked state, enabling release with minimal force by simply reversing the deformation.
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 reduces the maximum inserting force required, minimizes chattering, and decreases the force needed for fitting and releasing, ensuring accurate and defect-free connections while maintaining the fitted state with reduced operational effort.
Implementation Method 1
a lance made of a resilient member and formed on an inner wall of the terminal receiving cavity is engaged with a locking hole formed in a tubular portion having a resiliently deformable contact member therein of the female terminal
Implementation Method 2
the male terminal housing and the female terminal housing are fitted to each other to allow the male terminal to be in sliding contact with the contact member of the female terminal
Data Source
AI summary
A connector includes: a female terminal housing provided with a terminal receiving cavity receiving a female terminal; and a male terminal housing retaining a male terminal to be connected to the female terminal. The male and female terminal housings have first and second engagement portions. The male and female terminal housings are fitted in a first fitting position by the first engagement portion. The male and female terminal housings are fitted in a second fitting position by the second engagement portion. The first fitting position is a position in which the locking hole of the female terminal is engaged with the lance of the terminal receiving cavity, and in which the male terminal is not in sliding contact with the female terminal. The second fitting position is a position in which the male terminal is in sliding contact with the female terminal.