Connector Terminal Assurance with Two-Axis Locking for Dielectric Spacing
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Solution Overview
Problem
In high terminal density connectors, the flush stop surface in the groove leads to low dielectric strength and leakage paths due to the close proximity of terminals, which is exacerbated by the need for precise alignment of the terminal position assurance device.
Innovation Solution
The introduction of a terminal position assurance device with a locking mechanism that can move towards the stop surface through a non-transverse movement, including a cam-type or rotational motion with components parallel to the terminal's longitudinal direction, allowing for increased distance between terminals and improved dielectric strength by using protuberances and inclined ramps to guide the locking means into position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the stop surface of the terminal lies flush in the groove to enable precise guidance of the terminal position assurance device, then the alignment precision is improved, but the distance between neighbouring terminals is reduced leading to low dielectric strength and leakage paths
Solution Approach 1:
The patent introduces a cam-type movement mechanism that converts transverse movement into longitudinal movement. The cam surface transforms the motion path of the locking means from a single-dimensional transverse path into a two-dimensional path with both transverse and longitudinal components, allowing the locking means to approach the stop surface without requiring the stop surface to be flush with the groove
Solution Approach 2:
The patent employs a dynamic cam mechanism where the cam surface geometry varies along the movement path. This dynamic geometry allows the locking means to be guided smoothly from an initial position to a final locked position, maintaining precise alignment while enabling controlled approach to the stop surface with optimized spacing
2Productivity
If the distance between neighbouring terminals is reduced to achieve high terminal density, then the productivity is improved, but the dielectric strength decreases and leakage paths are created
Solution Approach 1:
The patent segments the locking function into two independent elements: a pushing element that performs transverse movement and a locking means element that performs the actual locking. This segmentation allows the locking means to be positioned optimally for dielectric strength while the pushing element handles the guidance function, enabling high terminal density without compromising reliability
3Reliability
If a terminal position assurance device with locking means is introduced to ensure correct positioning, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The patent merges the guidance function and locking function into a single integrated terminal position assurance device. The pushing element and locking means work together as one unit, eliminating the need for separate guidance mechanisms and reducing overall device complexity while maintaining high positioning accuracy
Data Source
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AI summary
Connector comprising a housing (4) made of a dielectric material, in which cells (7) are formed. Terminals (5) are housed in the cells (7) and extend essentially in a longitudinal direction (L). The housing (4) is also equipped with a terminal position assurance device (2), having locking means (26) interacting with a stop surface (8) located on the terminal (5). The terminal position assurance device (2) may possibly have a system of ramps arranged to move the locking means (26) sequentially, perpendicularly to the longitudinal direction (L), and then parallel to the longitudinal direction (L). The leakage path between two terminals (5) can then be lengthened.