Connector Lance Beak Breakage Prevention via Projected Part Override
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Solution Overview
Problem
Conventional connectors face issues where the lance beak part is prone to breaking due to excessive load when the terminal is incompletely inserted, making it difficult to determine the complete insertion state and risking damage to the locking lance.
Innovation Solution
The connector design features a projected part that overrides the lance beak part, distributing the force to a more rigid locking projection, and includes inclined faces to guide the projected part onto the locking projection, reducing the risk of breaking the lance beak part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the locking lance is made flexible to allow deflection during terminal insertion, then the terminal can be securely locked in the completely inserted state, but the lance beak part becomes prone to breaking when excessive load is applied in the incompletely inserted state
Solution Approach 1:
The locking lance is designed with non-uniform cross-sectional dimensions, where the lance beak part has smaller width and thickness compared to the main body. This local quality variation allows the lance to be flexible enough for locking while directing excessive loads to the more robust locking projection area, preventing breakage at the beak part
Solution Approach 2:
The projected part of the front holder acts as an intermediary that detects the insertion state by contacting either the lance beak part (incompletely inserted) or the locking projection (completely inserted). This intermediary mechanism allows detection without requiring the lance beak part to withstand excessive loading
2Difficulty of detecting and measuring
If the projected part of the front holder contacts the lance beak part to detect incomplete insertion, then the insertion state can be detected, but excessive load may be applied to the lance beak part causing it to break
Solution Approach 1:
The locking lance has different structural characteristics at different locations: the lance beak part is thinner for flexibility, while the locking projection area is more robust. The projected part is designed to contact the locking projection (more robust area) when the terminal is completely inserted, rather than continuously contacting the fragile beak part, thus enabling detection while avoiding excessive loading
3Ease of operation
If the lance beak part is made thinner and more flexible for easy engagement with the lock releasing jig, then the lock can be easily released, but the lance beak part becomes more susceptible to breaking under excessive load
Solution Approach 1:
The locking lance features localized thinning at the beak part to facilitate easy engagement with the lock releasing jig, while the main body and locking projection area maintain sufficient thickness for strength. This local quality differentiation allows the thin beak part to be easily manipulated for lock release while the robust locking projection area withstands excessive loads during insertion detection
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 prevents the lance beak part from breaking under large loads and allows for accurate detection of complete terminal insertion by guiding the projected part onto a more robust locking projection, ensuring secure engagement without damaging the locking lance.
Implementation Method 1
a flexible locking lance that locks a terminal to be inserted in the connector housing... When the terminal 12 is inserted into the terminal containing room 11, the locking projection 14 of the locking lance 13 is brought into contact with the base plate portion 12b and deflected
Data Source
AI summary
To provide a connector in which a lance beak part will not be broken, even though a large load is applied by a front holder. A locking lance is provided, at its distal end, with a lance beak pad which is adapted to be caught by a lock releasing jig for releasing lock of the locking lance with respect to a terminal, and a locking projection which is continued from the lance beak part and erected from a terminal end of the lance beak part. When a projected part is inserted into e deflection space in a state where the locking lance is deflected, a lower face of the projected part overrides an upper face of the lance beak part, and a distal end of the projected part comes into contact with a vertical face of the locking projection which is erected from the lance beak part.