Connector Housing Lock Assurance for Full Coupling Alignment
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Solution Overview
Problem
Existing connector systems lack effective mechanisms to ensure secure engagement and proper alignment of male and female housings, particularly when terminal position assurance devices are used, leading to potential misalignment and improper connection.
Innovation Solution
A connector position assurance (CPA) device is inserted into the female housing before engagement, transitioning through pre-lock and full-lock positions to ensure secure coupling with the male housing, while an optional terminal position assurance (TPA) device secures terminals within the female housing, transitioning similarly to facilitate full insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a TPA device is used to secure terminals in the female housing, then terminal positioning is improved, but the outer dimension of the female housing increases making insertion difficult
Solution Approach 1:
The TPA device incorporates flexible members that can dynamically change position between a first position (extending outward for terminal securing) and a second position (retracted for insertion). This dynamic positioning allows the device to adapt its outer dimension based on operational requirements, resolving the contradiction between terminal positioning precision and insertion ease.
Solution Approach 2:
The TPA device is divided into separate functional components: a body portion, flexible members, and positioning features. This segmentation allows the flexible members to be independently positioned and controlled, enabling the device to maintain terminal securing capability while reducing overall outer dimension during insertion operations.
2Reliability
If the TPA device extends outward to secure terminals, then terminal securing is improved, but the outer dimension becomes too large to fit into the male housing
Solution Approach 1:
The flexible members of the TPA device can dynamically transition between extended and retracted positions. When extended, they provide reliable terminal securing; when retracted, they reduce the outer dimension to fit within the male housing, thus resolving the contradiction between terminal securing reliability and volume constraints.
Solution Approach 2:
The flexible members can be nested within or retracted into the body portion of the TPA device, allowing the overall outer dimension to be minimized while maintaining the terminal securing functionality when needed. This nesting capability resolves the contradiction by allowing the device to contain its functional elements within a compact form factor.
Data Source
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AI summary
A connector position assurance device having multiple features for assuring a full coupling and locking of a female housing with a male housing in a connector system, such that the female housing and male housing are placed into a fully coupled and locked position when the connector position assurance device is moved from a pre-lock position to a full-lock position. When the connector position assurance device is at a full-lock position, a first member on the connector position assurance penetrates a window formed on the female housing, and at least one ledge extending from the connector position assurance device prevents a flexible member of the female housing from being moved downward, providing assurance that the female and male housings are fully coupled and locked together.