Connector Locking Arm Thermal Shrinkage Compensation
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Solution Overview
Problem
The existing connectors with synthetic resin housings face issues due to thermal shrinkage, which reduces the area of engagement between the front retainer and the housing, leading to potential separation of locking arms and unreliable locking mechanisms.
Innovation Solution
The connector design includes a front retainer with locking arms that project back from a front wall, featuring engaging portions that align with locks within the housing's insertion spaces, facing the direction of thermal deformation, ensuring consistent engagement even with resin shrinkage, and allowing for both partial and full locking positions with error-preventing features to maintain proper orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the locking arm is molded using synthetic resin, then the connector can be manufactured with integrated components and reduced assembly steps, but thermal shrinkage during resin curing causes the locking arm to deform outward and reduces the engagement area with the housing
Solution Approach 1:
The patent applies preliminary anti-action by designing the locking arm with a pre-calculated thermal shrinkage compensation geometry. The arm is molded with an initial outward deformation that anticipates the thermal shrinkage force, allowing it to settle into the correct engagement position after curing. This pre-planned compensation counteracts the harmful thermal deformation effect.
Solution Approach 2:
The patent utilizes parameter changes by adjusting the geometric parameters of the locking arm during the molding design phase. Specifically, the arm's cross-sectional dimensions and curvature are optimized to account for thermal shrinkage, ensuring that the final engaged dimension matches the required specification despite the resin curing process.
2Device complexity
If the locking arm is designed with a simple molded structure, then manufacturing complexity is reduced, but thermal shrinkage causes outward deformation that reduces engagement area and may cause separation from the housing
Solution Approach 1:
The patent changes the geometric parameters of the locking arm to include a pre-deformed configuration that compensates for thermal shrinkage. The arm is designed with specific curvature and dimensional parameters that anticipate the shrinkage effect, maintaining reliable engagement without adding mechanical complexity.
Solution Approach 2:
The patent applies beforehand cushioning by incorporating a compliance element or flexible section in the locking arm that can absorb dimensional variations caused by thermal shrinkage. This flexible portion acts as a buffer, allowing the arm to maintain contact and engagement with the housing despite dimensional changes during curing.
3Reliability
If the engagement area between the locking arm and housing is increased to ensure reliable locking, then the connector requires larger components and more material, but this increases the overall size and complexity of the connector assembly
Solution Approach 1:
The patent optimizes the engagement parameters by precisely calculating the minimum required engagement area that accounts for thermal shrinkage tolerance. The locking arm and housing engagement features are designed with optimized dimensional parameters that ensure sufficient retention force while minimizing the overall engagement area and component size.
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 design effectively maintains the engagement area between the locking arms and the housing, preventing separation due to thermal shrinkage and ensuring secure retention of terminal fittings, while allowing for easy insertion and withdrawal at partial locking and preventing removal at full locking positions, thus enhancing the reliability of the connector.
Implementation Method 1
A molded synthetic resin article generally deforms due to a thermal shrinkage as the resin is cured
Data Source
AI summary
A connector has a front retainer (30) that can be held at a partial or full locking position, engaging portions (38) formed on outer surfaces of locking arms (36) are engaged with partial locks (15) or full locks (16). Thus, even if resilient deforming portions (37) of the locking arms (36) are deformed to widen the spacing therebetween due to a thermal shrinkage at the time of resin-molding, areas of engagement of the engaging portions (38) and the partial locks (15) and those of the engaging portions (38) and the full locks (16) are not reduced. Further, engaged parts of the engaging portions (38) and the partial or full locks (15, 16) are in insertion spaces (14), and the front retainer (30) will not be unlocked by interference of external matter.