Connector Locking Arm Structure Without Torsional Hinges

Solution Overview

Problem

Existing electrical connectors with tortional hinges are prone to mechanical fatigue and breakage, especially in high temperature applications, limiting their reliability and durability.

Innovation Solution

The connector design incorporates a flexible linking member with a U-shaped cross-section, eliminating the need for tortional hinges and providing a secure and reliable pivot mechanism for the locking arm.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If tortional hinges are used to enable pivotal movement of the locking arm, then the connector can be manufactured with simpler structure, but the hinges are prone to mechanical fatigue and breakage, reducing reliability

Engineering Contradiction:

Improvestructural simplicityVSAvoiddurability of locking mechanism

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent removes the tortional hinges from the system entirely. Instead of using hinges to enable pivotal movement of the locking arm, the invention integrates the locking arm directly into the housing with its pivot points formed as part of the molded structure, eliminating the separate hinge components that were prone to fatigue and breakage.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The locking arm and housing are merged into a single integrated component. The locking arm is molded as an integral part of the housing, with pivot points formed directly in the housing structure. This integration eliminates the need for separate hinge components and reduces the number of parts, thereby improving reliability while maintaining manufacturability.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If the size of tortional hinges is increased to improve mechanical durability, then the durability may be improved, but the increased stiffness impairs the movement of the locking arm

Engineering Contradiction:

Improvemechanical durabilityVSAvoidmovement of locking arm

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The locking arm and housing are merged into a single integrated component. The locking arm is molded as an integral part of the housing, with pivot points formed directly in the housing structure. This integration eliminates the need for separate hinge components and reduces the number of parts, thereby improving reliability while maintaining manufacturability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent changes the physical parameters of the locking mechanism by eliminating the hinge structure entirely. Instead of modifying hinge size and stiffness parameters, the invention uses a different structural approach where the locking arm pivots on points formed in the molded housing, allowing for optimized movement characteristics without the compromises required by hinge-based systems.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If tortional hinges are used in the connector design, then the connector can be manufactured with simpler structure, but the hinges are unreliable in high temperature applications

Engineering Contradiction:

Improvestructural simplicityVSAvoidhigh temperature reliability

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The patent removes the tortional hinges from the system entirely. Instead of using hinges to enable pivotal movement of the locking arm, the invention integrates the locking arm directly into the housing with its pivot points formed as part of the molded structure, eliminating the separate hinge components that were prone to fatigue and breakage.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs advanced composite materials, specifically fiberglass-reinforced plastic, for the housing and locking arm assembly. This material selection provides superior high-temperature reliability and mechanical strength compared to conventional materials, enabling the connector to withstand elevated temperatures while maintaining structural integrity and locking mechanism reliability.

Inventive Principle:

Principle #40Composite materials

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 enhances the connector's reliability and durability, allowing it to withstand high temperatures and reducing the force required for locking and releasing, while also enabling the use of advanced materials like fiberglass.

Implementation Method 1

The linking member is configured to be flexible, allowing for the two legs to at least partially deflect such that the locking arm is pivoting from the locked position to the unlocked position.

Methodology Applied

Scientific EffectFlexing: Elasticity

Data Source

PatentUS20250174940A1Connector with Durable Locking Mechanism

Publication Date: 2025.05.29 APTIV TECHNOLOGIES AG

AI summary

A connector includes a housing and a locking arm designed to secure the connector to a corresponding counter connector. The locking arm is pivotable between a lock position and a release position. A linking member connects the locking arm to the housing, including a first leg attached to the housing, a second leg attached to the locking arm, and a base portion connecting the first and second legs. The linking member is configured to be flexible, allowing the legs to partially deflect, enabling the locking arm to pivot from the locked to the release position. The base portion is positioned between the first and second legs, extending from the center of the housing towards its outer side, with the first leg located farther towards the outer side than the second leg.