Cantilevered Latch Arcuate Protrusions for Connector Durability
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Solution Overview
Problem
Existing electrical connectors face challenges in achieving reliable and durable mating cycles due to stress on materials, particularly in connectors made from glass-filled polymeric dielectric materials, which often result in premature failure under repeated use.
Innovation Solution
A connector assembly featuring a cantilevered latch with specifically designed arcuate protrusions and ramp angles, allowing for controlled engagement and distribution of stress within the material, preventing principal stress from exceeding the yield strength of the 33% glass-filled polymeric dielectric material, thereby enhancing cyclic durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connector designs are used with glass-filled polymeric dielectric materials, then manufacturing cost and material strength are maintained, but cyclic durability deteriorates due to stress concentration exceeding yield strength
Solution Approach 1:
The latch incorporates arcuate protrusions with specific radii (first radius and second radius) that create curved stress distribution paths. These curved geometries prevent stress concentration by distributing principal stresses more evenly throughout the glass-filled polymeric dielectric material, keeping stresses below the yield strength threshold during repeated mating cycles.
Solution Approach 2:
The invention modifies geometric parameters including ramp angles, arcuate protrusion radii, and latch arm dimensions to optimize stress distribution. By carefully selecting these parameters, the design ensures that principal stresses remain within acceptable limits for the glass-filled polymeric material while maintaining functional performance.
2Ease of manufacture
If the latch structure is simplified for ease of manufacture, then manufacturing complexity is reduced, but stress distribution capability deteriorates leading to premature failure
Solution Approach 1:
The latch is divided into distinct functional segments including the latch arm, first arcuate protrusion, second arcuate protrusion, and engagement features. This segmentation allows each element to be optimized for its specific function while maintaining overall manufacturability through integration into a single molded component.
Solution Approach 2:
The latch utilizes glass-filled polymeric dielectric material that combines the benefits of polymer ease of molding with the strength and dimensional stability of glass reinforcement. This composite material enables complex stress-distributing geometries to be manufactured while maintaining the required mechanical properties.
3Force
If the ramp angle is increased to improve engagement force, then locking reliability is enhanced, but stress on the polymeric material increases causing premature failure
Solution Approach 1:
The arcuate protrusions with optimized radii create gradual curved transitions that distribute the engagement force over a larger area and longer path. This curvature prevents sharp stress concentrations that would occur with abrupt angular transitions, allowing higher engagement forces to be achieved while keeping material stresses below the yield strength of the glass-filled polymer.
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 assembly achieves a significant increase in cyclic durability, supporting up to five times more mating/unmating cycles without failure, by effectively managing stress and maintaining the material within its yield strength limits.
Implementation Method 1
preventing principal stress from exceeding the yield strength of the 33% glass-filled polymeric dielectric material
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A connector assembly (10) includes a first-connector (12) and a second-connector (16). The first-connector (12) has a locking-lug (14). The second-connector (16) has a cantilevered latch (18) configured to slideably engage the locking-lug (14). The cantilevered latch (18) includes a pair of parallel latch-arms (26). The pair of parallel latch-arms (26) terminate at a first cross-beam (32) that spans the pair of parallel latch-arms (26). The cantilevered latch (18) further includes a second cross-beam (34) parallel to the first cross-beam (32). The second cross-beam (34) is configured to releasably lock the locking-lug (14) when the first-connector (12) is mated with the second-connector (16). The pair of parallel latch-arms (26) includes a rib (36) extending beyond a bottom-surface (38) of each individual latch-arm (26). The locking-lug (14) deflects the pair of parallel latch-arms (26) toward an outer-surface (24) of the second-connector (16) when first-connector (12) is moved from an unmated-position (20) to a mated-position (22), whereby the rib (36) contacts the outer-surface (24) and limits a deflection of the pair of parallel latch-arms (26).