Connector Lock Reinforcement Inhibits Buckling
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Solution Overview
Problem
Existing electrical connector assemblies lack sufficient retention force and durability, particularly under removal forces, due to inadequate locking mechanisms that can lead to buckling and rotation of locking fingers, resulting in reduced reliability and increased risk of accidental disconnection.
Innovation Solution
Incorporation of a lock-reinforcement feature within the connector assembly that engages the cantilevered locking-finger ribs, providing additional support and increasing the effective column length, thereby inhibiting buckling and rotation of the locking-ramp, and enhancing the retention force by utilizing a sliding engagement mechanism that maximizes the cross-sectional area of the locking-ramp in the shear plane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cantilevered locking-finger with locking-ramp is used to retain the electrical-terminal, then the connector assembly achieves basic locking function, but the locking-finger is susceptible to buckling and rotation under removal forces, reducing retention force
Solution Approach 1:
The lock-reinforcement feature introduces a new dimensional element by extending along the longitudinal-axis and engaging the locking-finger at multiple points (tip and body), creating a three-dimensional reinforcement structure that prevents buckling and rotation without interfering with the primary locking function
Solution Approach 2:
The connector assembly combines the polymeric housing material with the lock-reinforcement feature to create a composite locking structure that leverages the flexibility of the polymeric material while adding structural rigidity through the reinforcement geometry
2Ease of operation
If the locking-finger is designed to be cantilevered for ease of operation, then the locking mechanism is easy to engage, but the cantilevered structure has reduced structural stability and is prone to deformation under load
Solution Approach 1:
The lock-reinforcement feature is segmented into distinct engagement zones: one at the tip of the locking-finger and another at the body, allowing independent reinforcement of different structural weak points while maintaining the overall cantilevered configuration
Solution Approach 2:
The reinforcement is applied locally at critical stress points (tip and body of the locking-finger) rather than uniformly across the entire structure, providing targeted stability enhancement where buckling and rotation are most likely to occur
Data Source
AI summary
A connector assembly includes an electrical-terminal, a housing, and a lock-reinforcement. The a housing defines a cavity configured to receive the electrical-terminal. The housing includes a locking-finger overlaying the electrical-terminal configured to lock the electrical-terminal within the cavity. The locking-finger has a rib protruding from the locking-finger having a first-surface and a second-surface. A tip of the locking-finger includes a locking-ramp projecting from the locking-finger configured to engage a perimeter-edge of a lock-slot defined by the electrical-terminal. The lock-reinforcement is disposed within the cavity and configured to slideably engage both the first-surface and the second-surface of the rib after the lock-reinforcement is moved from a pre-stage-position to a seated-position. The lock-reinforcement is configured to inhibit a buckling of the cantilevered locking-finger when a removal-force is applied to the electrical-terminal when the lock-reinforcement is in the seated-position, thereby inhibiting the locking-ramp from rotating within the lock-slot of the electrical-terminal.