Connector Locking Holder Segmentation Strategy

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Solution Overview

Problem

Conventional vehicle connectors with locking mechanisms increase complexity and cost, and are prone to failures due to improper connection during assembly, leading to costly warranty claims and module failures, especially in automotive lighting systems.

Innovation Solution

A connector locking holder system that secures the connector in a connected state using a holder and attachment mechanism, eliminating the need for a locking mechanism on the connector itself, ensuring proper connection and preventing disconnection through a pocket and fastening system that verifies the connector's state and resists vibration-induced separation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a locking mechanism is provided on the connector itself, then the connector connection reliability is improved, but the device complexity and cost increase

Engineering Contradiction:

Improveconnector connection reliabilityVSAvoidconnector structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The locking function is segmented from the connector body and transferred to a separate holder component. The holder includes a pocket with restricting features that prevent disconnection, while the connector itself remains simple without integrated locking mechanisms. This segmentation resolves the contradiction by providing reliability through the holder's restricting features while maintaining simplicity in the connector design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The holder acts as an intermediary component between the connector and the assembly housing. It provides the locking/restricting function through its pocket and restricting features, while the connector maintains its basic connection function. This intermediary approach allows the connector to remain simple while still achieving reliable connection through the holder's intervention.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a locking mechanism is provided on the connector itself, then the connector connection reliability is improved, but the manufacturing cost increases

Engineering Contradiction:

Improveconnector connection reliabilityVSAvoidconnector manufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The locking function is segmented from the connector body and transferred to a separate holder component. This allows the connector to be manufactured as a simple, low-cost component while the holder (which provides the locking function) can be manufactured separately and attached to the assembly housing, potentially using simpler and less expensive processes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The holder can be designed as a simple, inexpensive component that provides the necessary locking function through its pocket and restricting features. By using a simple holder structure rather than a complex integrated locking mechanism, the overall manufacturing cost is reduced while maintaining connection reliability.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Stability of the object's composition

If the connector is secured using a holder with pocket and restricting features, then the connector stability is improved, but the device complexity increases

Engineering Contradiction:

Improveconnector stabilityVSAvoidholder structure complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The holder provides stability through localized restricting features within its pocket, rather than requiring a complex overall structure. The restricting features are positioned at specific locations to prevent disconnection in the vertical direction while allowing horizontal insertion. This localized approach provides stability without requiring complex holder geometry throughout the entire structure.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Instead of providing stability through a complex active locking mechanism that actively engages, the holder uses passive restricting features that physically block disconnection. The pocket geometry itself provides the stabilizing function through its shape and restricting features, rather than through active mechanical engagement mechanisms.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS10044142B1Connector locking holder

Publication Date: 2018.08.07 VALEO NORTH AMERICA INC(US)

AI summary

A connector locking holder includes an electrical connector having a first connector body with a first electrical contact, and a second connector body with a second electrical contact. The first connector body is configured to be coupled to the second connector body to provide the connector in a connected state in which the first and second electrical contacts are electrically connected to each other. A holder is configured to secure the connector to an assembly which includes the connector. An attachment is configured to attach the connector to the holder only when the connector is in said connected state.