Connector Housing Lance with Clearance for Locking Reliability
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Solution Overview
Problem
Existing housing designs for connectors face challenges in reliably locking terminals while maintaining efficient assembly, as increased rigidity of locking mechanisms requires higher insertion forces, making assembly difficult.
Innovation Solution
A housing design featuring a deflectable lance with a locking portion, clearance portion, and boundary portion, where the lance deflects in one direction when a terminal is inserted and returns in another to securely lock the terminal, reducing interference and increasing locking force without increasing assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigidity of the lance is increased to improve locking reliability, then locking force is improved, but insertion force required increases making assembly difficult
Solution Approach 1:
The distal end portion of the lance is segmented into three functional regions: locking portion, clearance portion, and boundary portion. This segmentation allows each region to serve a specific purpose - the locking portion provides locking force, the clearance portion reduces interference during deflection, and the boundary portion transitions between them. This resolves the contradiction by enabling reliable locking without requiring uniformly high rigidity throughout the entire lance.
Solution Approach 2:
Different regions of the lance distal end are given different geometric properties tailored to their functions. The locking portion has edges disposed away from the boundary portion toward the rear side, creating a localized geometry optimized for locking. The clearance portion provides space for deflection movement. This local differentiation allows the lance to achieve reliable locking where needed while maintaining ease of insertion through strategic clearance zones.
2Strength
If rigidity of the lance is increased to prevent deformation under pull force, then locking force is improved, but the lance requires higher insertion force making assembling work difficult
Solution Approach 1:
The lance is designed to be dynamically deflectable during the insertion process rather than being completely rigid. The clearance portion at the distal end allows the lance to deflect in the first direction during insertion, reducing the force required. After insertion, the lance returns to its original position to provide locking. This dynamic behavior resolves the contradiction by allowing flexibility during assembly while maintaining strength for locking.
Solution Approach 2:
The clearance portion is pre-configured in the lance structure to anticipate and accommodate the deflection that occurs during insertion. By providing this clearance space in advance, the design prevents interference between the lance and terminal during the insertion process, reducing the force needed without compromising the subsequent locking action.
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 design ensures reliable locking of terminals with increased locking force without complicating the assembly process, maintaining efficient assembly and preventing terminal disconnection due to vibrations.
Implementation Method 1
a lace configured to deflect in a first direction when the terminal is inserted into the terminal accommodating chamber and pushes the lace out of the terminal accommodating chamber
Implementation Method 2
to return in a second direction when the terminal is further inserted to lock the abutting portion of the terminal at a distal end portion of the lace
Data Source
AI summary
A housing includes a terminal accommodating chamber and a lance. The lance includes a locking portion configured to lock the abutting edge of the terminal, a clearance portion, and a boundary portion between the locking portion and the escape portion. The locking portion is provided on one side of the boundary portion toward which the lance deflects in the first direction, and the clearance portion being provided on another side of the boundary portion toward which the lance returns in the second direction. An edge of the locking portion on a side opposite to the boundary portion and an edge of the clearance portion on a side opposite to the boundary portion are disposed away from the boundary portion toward the rear side of the housing from which the terminal is inserted.