Electrical Connector Maximizing Circuit Isolation Distance

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Solution Overview

Problem

Electrical connectors used in the automotive industry lack sufficient circuit-to-circuit isolation distance and fail to ensure secure locking of socket contacts in the female connector assembly, which are critical for performance in this sector.

Innovation Solution

The design features a male connector assembly with pin contacts housed in individual chambers with solid sidewalls and a female connector assembly with socket contacts in tower elements, including a terminal position assurance cap with flexible fingers to ensure maximum circuit-to-circuit isolation and a flexible integral retention clip for secure socket contact retention, along with a novel method for removing socket contacts using a servicing tool.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional electrical connector designs are used, then the connector structure is simple, but the circuit-to-circuit isolation distance is insufficient and socket contact locking is not secure

Engineering Contradiction:

Improvecircuit-to-circuit isolation distanceVSAvoidconnector structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The female connector assembly is segmented into multiple tower elements, each housing individual socket contacts in separate chambers. This segmentation isolates each circuit path, ensuring adequate circuit-to-circuit isolation distance while maintaining a compact overall structure. Each tower element acts as an independent isolation unit.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The terminal position assurance cap is nested within the female connector assembly, with fingers that insert into chambers alongside socket contacts. This nested configuration allows the isolation assurance mechanism to be integrated without significantly increasing external dimensions, resolving the contradiction between isolation distance and structural complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If traditional electrical connector designs are used, then the connector is easy to manufacture, but the socket contact locking mechanism is insufficient for automotive industry requirements

Engineering Contradiction:

Improvesocket contact locking securityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The terminal position assurance cap is designed to be installed before final connector assembly, preliminarily securing socket contacts in their correct positions and locking states. This preliminary action ensures proper locking mechanism engagement and reduces the risk of assembly errors, meeting automotive industry reliability requirements while maintaining manufacturing feasibility.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The flexible fingers of the terminal position assurance cap act as intermediaries between the socket contacts and the chamber walls, providing secure locking through elastic engagement. This intermediary mechanism achieves reliable socket contact retention without requiring complex direct locking structures, balancing manufacturing ease with locking security.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If socket contacts are securely retained in the female connector assembly, then connection reliability is improved, but socket contact removal becomes difficult

Engineering Contradiction:

Improvesocket contact retention securityVSAvoidsocket contact removal ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The retention mechanism uses flexible fingers that can dynamically change their engagement state. During normal operation, the fingers securely retain socket contacts. During maintenance, when appropriate force is applied, the fingers can flex to release the socket contacts. This dynamic behavior resolves the contradiction between secure retention and easy removal.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The design allows for temporary discarding of the secure retention state during maintenance operations, enabling socket contact removal when needed. After maintenance, the retention mechanism can be recovered to its secure state, allowing socket contacts to be reinstalled and firmly retained. This cyclical retention-release-retention pattern satisfies both reliability and maintainability requirements.

Inventive Principle:

Principle #34Discarding and recovering

Data Source

PatentUS9033736B2Electrical connector with maximized circuit-to-circuit isolation distance

Publication Date: 2015.05.19 JST CORP

AI summary

An electrical connector having a male connector assembly of an insulating material for housing a plurality of pin contacts, and a female connector assembly of an insulating material, for housing a plurality of socket contacts for mating with the pin contacts. A circuit-to-circuit isolation distance is at least twice a connector mating distance, when the male and female connector assemblies are mated. A terminal position assurance cap, insertable from an end of the female connector assembly opposite an insertion face for the male connector assembly enables a maximized circuit-to-circuit isolation distance. The terminal position assurance cap assures that the socket contact is retained in the socket contact chamber, by blocking a flexible integral retention clip against the socket contact. The connector further includes an arrangement for removing the socket contact from the female connector assembly.