Connector Primary Lock Reinforcement for Terminal Seating Detection

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Solution Overview

Problem

Existing connector assemblies face issues with insufficient blocking force and improper detection of terminal seating within the terminal cavity, leading to potential misalignment and instability.

Innovation Solution

A connector assembly design featuring a cantilevered resilient primary and secondary terminal locking arms, with a secondary arm flexing outward to clear a blocking condition upon terminal insertion, allowing the PLR device to move from a pre-staged to a fully staged position, and a side wall offset by 90 degrees inhibiting outward flexing of the primary arm.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If a resilient terminal lock and primary lock reinforcement device are used to inhibit movement, then the connector assembly provides blocking force to prevent premature movement, but the blocking force is insufficient and proper detection of terminal seating is not achieved

Engineering Contradiction:

Improveblocking forceVSAvoidterminal seating detection

Core Design Contradiction:

ForceVSReliability

Solution Approach 1:

The PLR device transitions from a static blocking position to a dynamic responsive position. The resilient secondary locking arm flexes dynamically in response to terminal insertion forces, automatically transitioning the PLR device from pre-staged to fully staged position when the terminal is properly seated, thereby providing both sufficient blocking force and reliable seating detection

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the physical state of the PLR device from a fixed pre-staged position to a movable fully staged position. This parameter change is triggered by the terminal insertion process itself, where the terminal's interaction with the resilient locking arm causes the PLR device to move, providing both force and detection functionality

Inventive Principle:

Principle #35Parameter changes

2Stability of the object's composition

If the PLR device is positioned to provide blocking force, then movement is prevented, but the device cannot detect whether the terminal is properly seated

Engineering Contradiction:

Improveconnector stabilityVSAvoidterminal engagement detection

Core Design Contradiction:

Stability of the object's compositionVSDifficulty of detecting and measuring

Solution Approach 1:

The resilient secondary locking arm provides mechanical feedback about terminal seating status. When the terminal is properly inserted, it contacts and flexes the locking arm, which automatically moves the PLR device to the fully staged position. This feedback mechanism simultaneously maintains stability through the blocking function and detects proper engagement through the automatic position transition

Inventive Principle:

Principle #23Feedback

3Ease of operation

If the secondary terminal locking arm is used to clear the blocking condition, then the PLR device can move to the fully staged position, but the primary terminal locking arm may flex outwardly causing instability

Engineering Contradiction:

ImprovePLR device movementVSAvoidlocking arm stability

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The side wall is positioned asymmetrically at a 90-degree offset from the secondary locking arm. This asymmetric geometry creates a selective constraint that allows the locking arm to flex in the direction needed to move the PLR device while preventing outward flexing that would compromise stability. The asymmetric design enables directional movement control

Inventive Principle:

Principle #4Asymmetry

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

Ensures secure terminal seating by providing a sufficient blocking force and proper detection of terminal engagement, enhancing stability and reliability of the connector assembly.

Implementation Method 1

a cantilevered resilient primary terminal locking arm configured to secure the terminal within the terminal cavity... a cantilevered resilient secondary terminal locking arm configured to inhibit the PLR device from moving... The secondary terminal locking arm flexes outwardly due to contact with the terminal release ramp

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS12418131B2Primary lock reinforcement for connector locking system with resilient and rigid locking surfaces

Publication Date: 2025.09.16 APTIV TECHNOLOGIES AG

AI summary

A connector assembly includes a connector body having a terminal cavity and a cantilevered resilient primary terminal locking arm configured to secure a terminal. The terminal defines a terminal release ramp and a locking ridge. The connector assembly also includes a primary lock reinforcement (PLR) device having a cantilevered resilient secondary terminal locking arm that inhibits the PLR device from moving from a pre-staged position to a fully staged position prior to the terminal being inserted into the terminal cavity due to a blocking condition between the secondary terminal locking arm and a cavity wall of the terminal cavity. The secondary terminal locking arm flexes outwardly as the terminal is inserted within the terminal cavity, thereby clearing the blocking condition. The PLR device has a side wall that inhibits outward flexing of the primary terminal locking arm.