Electrical Connector Locking Pawl and CPA Element
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Solution Overview
Problem
Electrical connectors in motorized vehicle applications face challenges in maintaining a secure lock against vibrations, leading to potential unplugging, and existing solutions do not adequately ensure proper mating and secure connection.
Innovation Solution
An electrical connector assembly with enhanced locking means, featuring a primary locking pawl and a connection position assurance (CPA) element that engages only when properly mated, utilizing a mobile CPA lever and secondary locking member to prevent unintentional disengagement, ensuring the connectors remain securely locked.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a locking pawl with a second stop is used to engage the first stop, then the connectors are locked together, but the connection may still unintentionally disengage under vibration
Solution Approach 1:
The locking system is divided into two independent but coordinated locking mechanisms: a primary locking pawl with a second stop and a CPA element with a third stop. Both must be engaged simultaneously to achieve full locking, creating segmented redundancy that prevents vibration-induced disengagement.
Solution Approach 2:
The CPA element with its third stop acts as a preliminary protective measure against unintended disengagement. The third stop is positioned to engage the first stop only when the connectors are properly mated, providing advance protection against vibration before disengagement can occur.
2Manufacturing precision
If a CPA element is added to ensure proper mating position, then connection accuracy is improved, but the device complexity increases
Solution Approach 1:
The CPA element is integrated into the existing locking system architecture, sharing common components such as the first stop and housing structure. The CPA lever utilizes the existing slit in the locking pawl, merging the position assurance function with the locking mechanism rather than adding completely separate systems.
Solution Approach 2:
The CPA element serves multiple functions: it ensures proper mating position, provides an additional locking stop (third stop), and works in coordination with the primary locking pawl. The CPA lever itself acts as both a position indicator and a locking mechanism when engaged with the first stop.
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
The solution effectively prevents unintended unplugging by ensuring proper mating and secure locking, even under vibration, through the coordinated action of the locking pawl and CPA element, maintaining a stable connection.
Implementation Method 1
The locking pawl is elastically movable about the pivot point so as to allow the second locking stop to slide above the first locking stop and to be biased behind the first locking stop when the first and second connectors are mated
Data Source
AI summary
The electrical connector assembly comprises first and second connectors (102, 104) intended to mate with each other. One of the connectors (104) comprises a first locking stop (132) and the other of the connectors (102) comprises a primary locking pawl (134) carrying a second locking stop (142) intended to engage the first locking stop (132) so as to lock the first and second connectors (102, 104) when they are mated. The first connector (102) comprises a CPA element (146) movable from an initial position to a final position only when the first and second connectors (102, 104) are properly mated. The CPA element (146) is intended to engage, in the final position, the primary locking pawl (134) so as to prevent the first and second locking stops (132, 134) to disengage.