Electrical Connector Locking Structure for Vibration Retention

Solution Overview

Problem

Existing electrical connectors face issues with disconnection due to insufficient retaining force between the main body and locking part, particularly in complex environments, and existing solutions either lack sufficient retention force or increase complexity and cost.

Innovation Solution

An electrical connector design featuring a main shell with terminal channels and a terminal locking component comprising a terminal pressing plate and secondary limiting plate, which enhances locking by applying retaining force and defining the relative position between the main shell and the locking component.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a single locking plate or clip is used to secure terminals, then the design is simplified and assembly is easier, but the retention force is insufficient in high-vibration or thermal cycling environments

Engineering Contradiction:

Improveassembly simplicityVSAvoidretention force

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The locking mechanism is divided into two distinct components: a locking plate for terminal retention and a secondary limiting plate for connector retention. This segmentation allows each component to be optimized for its specific function, with the locking plate providing terminal securing and the secondary limiting plate providing enhanced retention force between the main body and locking component, preventing disconnection in high-vibration environments while maintaining assembly simplicity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The secondary limiting plate is nested within the locking component structure, integrating an additional retention mechanism without significantly increasing overall complexity. The secondary limiting plate is positioned between the main body and locking plate, creating a nested arrangement that provides enhanced retention force while maintaining a compact design that is relatively easy to manufacture

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If multiple components are added to enhance terminal retention, then the locking force is improved, but the device complexity and cost increase

Engineering Contradiction:

Improveterminal retentionVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The locking mechanism is divided into two distinct components: a locking plate for terminal retention and a secondary limiting plate for connector retention. This segmentation allows each component to be optimized for its specific function, with the locking plate providing terminal securing and the secondary limiting plate providing enhanced retention force between the main body and locking component, preventing disconnection in high-vibration environments while maintaining assembly simplicity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The secondary limiting plate serves multiple functions: it provides retention force between the main body and locking component, prevents disconnection in high-vibration environments, and works cooperatively with the locking plate to secure terminals. This multi-functionality allows a single additional component to address multiple retention needs without proportionally increasing complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If traditional friction-based locking is used, then the design is simple, but terminal misalignment or disconnection occurs under mechanical stress or vibration

Engineering Contradiction:

Improvelocking mechanism simplicityVSAvoidconnection stability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The secondary limiting plate is pre-configured with limiting protrusions that engage with corresponding features on the main body before the locking plate is fully secured. This preliminary action establishes a stable positional relationship and prevents misalignment from the outset, ensuring that subsequent terminal insertion and locking occur with proper alignment, thereby preventing disconnection under mechanical stress or vibration while maintaining design simplicity

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20250246840A1Electrical connector

Publication Date: 2025.07.31 APTIV CONNECTION SYSTEMS (NANTONG) CO LTD

AI summary

An electrical connector includes a main shell with one or more terminal channels extending in a first direction, designed to house terminals. The connector features a terminal locking component that mates with the main shell, comprising a base, a terminal pressing plate, and a secondary limiting plate. The terminal pressing plate applies a retaining force to the terminals within the channels, ensuring secure placement. The secondary limiting plate establishes a defined relative position between the main shell and the terminal locking component, enhancing stability and alignment. This configuration facilitates reliable electrical connections by maintaining terminal integrity and positional accuracy within the connector assembly.