Connector Primary Lock Reinforcement Sealing
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Solution Overview
Problem
Existing electrical connector assemblies face challenges in manufacturing efficiency and reliability due to complex configurations requiring multiple tools and lack of effective sealing against contaminants.
Innovation Solution
The electrical connector assembly incorporates a compressible primary lock reinforcement (PLR) with arcuate flexible-beams and retention-features that allow single injection molding and provide a tactile and visual indication of seating, ensuring secure retention and sealing through a specific engagement-force and sealing-ridge design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a complex configuration with multiple tools is used for manufacturing electrical connector assemblies, then manufacturing precision can be maintained, but productivity decreases and device complexity increases
Solution Approach 1:
The patent combines multiple manufacturing operations into a single injection molding process. The primary lock reinforcement (PLR) is molded directly into the connector housing in one operation, eliminating the need for separate tools and assembly steps for installing the PLR and inner-connector. This merging of operations directly improves productivity while reducing device complexity.
Solution Approach 2:
The single injection molding tool is designed to perform multiple functions: it forms the connector housing, creates the PLR structure, and integrates retention features all in one process. This multi-functional approach replaces what previously required multiple specialized tools, thereby improving manufacturing efficiency without sacrificing precision.
2Productivity
If a single injection molding process is used to manufacture the connector housing with PLR, then productivity improves and device complexity reduces, but manufacturing precision may be compromised
Solution Approach 1:
The injection molding process is segmented into distinct functional zones within the tooling design. The mold includes separate cavities and injection points for forming the housing, PLR, and retention features, allowing each element to be optimized for its specific dimensional requirements while being produced in a single cycle. This segmentation maintains precision despite the simplified single-step process.
3Device complexity
If the PLR is retained between arcuate flexible-beams without additional sealing mechanisms, then device complexity reduces, but reliability of sealing against contaminants deteriorates
Solution Approach 1:
The arcuate flexible-beams are designed to automatically provide both retention and sealing functions. When the PLR is retained between the beams, the flexible nature of the beams creates a self-sealing effect that prevents contaminant ingress without requiring additional sealing components. The structure serves itself by using the same flexible-beams for both retention and sealing purposes.
4Reliability
If the PLR is retained between arcuate flexible-beams with engagement-force, then reliability of retention improves, but the force required may increase device complexity
Solution Approach 1:
The arcuate flexible-beams provide dynamic retention through their elastic deformation characteristics. The beams flex to engage the PLR with sufficient force to prevent displacement, then maintain this engagement passively without requiring additional active retention mechanisms. This dynamic approach achieves reliable retention while keeping the structure simple.
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 solution enables efficient manufacturing with a single molding tool, eliminates the need for an inner-connector, and provides reliable sealing and retention forces sufficient to withstand typical vehicle operating conditions, reducing the risk of PLR displacement or contamination.
Implementation Method 1
The PLR includes a sealing-ridge configured to seal against contaminants when the PLR is moved from a pre-stage-position to a seated-position. The connector housing includes a pair of opposed arcuate flexible-beams that extend beyond an outer-wall of the connector housing.
Data Source
AI summary
An electrical connector includes an electrical-terminal, a connector-housing, and a primary-lock-reinforcement. The electrical-terminal is configured to receive a corresponding electrical-terminal. The connector-housing defines a first-aperture, a second-aperture, and a body. The connector-housing is configured to receive the electrical-terminal through the first-aperture along a longitudinal-axis of the connector-housing. The body defines a cavity having a cantilevered terminal-lock. The cantilevered terminal-lock terminates proximate an outer-wall of the body. The cantilevered terminal-lock is configured to releasably retain the electrical-terminal. The outer-wall defines an orifice positioned proximate a terminus of the cantilevered terminal-lock. The primary-lock-reinforcement is configured to support the terminus of the cantilevered terminal-lock. When the primary-lock-reinforcement is moved from a pre-stage-position to a seated-position the terminus is inhibited from deflecting away from the electrical-terminal along a mating-axis thereby sealing the orifice.