Connector Assembly Locking Reinforcement Device
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Solution Overview
Problem
Existing electrical connector assemblies fail to maintain component positions during shipping and handling, leading to inadvertent and premature movement of locking features, which can result in improper assembly and insertion of terminals into the connector housing.
Innovation Solution
The electrical connector assembly incorporates a primary-lock-reinforcement device (PLR-device) that slidesably engages the terminal tower, featuring a base, skirt, posts, ribs, locking tabs, and a beam to maintain the PLR-device in a shipping position until a specific lateral or longitudinal force is applied, allowing controlled movement through distinct stages to prevent premature activation and ensure proper assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the connector assembly uses a traditional locking mechanism without a shipping position, then the device complexity is reduced, but the reliability deteriorates due to inadvertent movement of locking features during shipping and handling
Solution Approach 1:
The primary-lock-reinforcement device is pre-configured in a shipping position that proactively prevents premature movement of locking features before the connector is actually assembled or activated. This preliminary positioning ensures that critical components remain secured during transport and handling operations.
Solution Approach 2:
The primary-lock-reinforcement device is divided into distinct functional segments including a shipping position feature, a locking feature, and a terminal engagement feature. This segmentation allows each component to perform its specific function independently while maintaining overall system reliability.
2Ease of operation
If the primary-lock-reinforcement device is designed to be movable during assembly, then the ease of operation is improved, but the stability deteriorates due to potential inadvertent movement before proper assembly
Solution Approach 1:
The primary-lock-reinforcement device transitions from a static locked position during shipping to a dynamic movable state during assembly operations. The device is designed to remain stable and fixed in its shipping position during transport, but can be easily moved to operational positions when proper assembly forces are applied by the operator.
Solution Approach 2:
The shipping position feature creates a preliminary counter-action that resists unwanted movement of the locking feature during shipping. This anti-action is designed to be overcome only by intentional assembly operations, ensuring that the device remains stable during transport but becomes movable when properly assembled.
3Manufacturing precision
If the connector assembly includes multiple positioning stages for the PLR-device, then the manufacturing precision is improved, but the device complexity increases due to additional structural components
Solution Approach 1:
The positioning mechanism is segmented into distinct stages including a shipping position and a first operational position, with each stage served by specific structural features such as the shipping position feature and the locking feature. This segmentation enables precise controlled positioning at each stage while maintaining clear functional separation.
Solution Approach 2:
The primary-lock-reinforcement device utilizes multi-dimensional movement capabilities, transitioning not only along the insertion axis but also laterally to engage different positioning features. This dimensional approach allows the device to achieve precise positioning in multiple stages without requiring overly complex single-axis mechanisms.
Data Source
AI summary
A connector-assembly includes a connector-housing and a primary-lock-reinforcement device. The connector-housing retains electrical-terminals within terminal-cavities defined by a terminal-tower disposed within the connector-housing. The electrical-terminals mate with one or more corresponding electrical-terminals along a mating-axis of the connector-assembly. The primary-lock-reinforcement device slideably engages the terminal-tower and is moveable from a shipping-position to a pre-stage-position. The primary-lock-reinforcement device has a base and a skirt. The primary-lock-reinforcement device has a post extending beyond an inner-surface of the skirt that engages a corresponding L-shaped slot defined by an outer-surface of the terminal-tower. The corresponding L-shaped slot has a first-leg and a second-leg. The first-leg defines a wall configured to inhibit a movement of the primary-lock-reinforcement device along the mating-axis. When the primary-lock-reinforcement device is moved from the shipping-position to the pre-stage-position, the post aligns with an entrance to the second-leg, thereby enabling the primary-lock-reinforcement device to move from the pre-stage-position to a full-stage-position.