Plastic Latch Integrated into Electrical Connector Cavity
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Solution Overview
Problem
Existing electrical connectors in aerospace and defense applications require permanent component retention without adhesives, as adhesives are costly and can compromise connection reliability by flowing to undesired areas.
Innovation Solution
An electrical connector design featuring a plastic latch integrated into the contact cavity, where latches are integrally formed on the rear insert and deform into contact-receiving openings to securely and permanently retain components within the shell, eliminating the need for adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive is applied to retain components in the housing, then permanent retention is achieved, but manufacturing cost increases and additional manufacturing steps are added
Solution Approach 1:
The patent extracts the retention function from the adhesive and relocates it to the insert itself by integrating latches into the insert. This eliminates the need for adhesive application steps while maintaining permanent retention capability.
Solution Approach 2:
The insert provides its own retention mechanism through integrated latches that engage with the housing, eliminating the need for external adhesive application. The insert serves both its primary function and the retention function simultaneously.
2Reliability
If adhesive is used for component retention, then permanent mounting is achieved, but manufacturing cost increases
Solution Approach 1:
The patent combines the retention function with the insert manufacturing process itself. The latches are formed as integral parts of the insert during molding, eliminating separate adhesive application steps and reducing overall manufacturing cost.
Solution Approach 2:
The insert provides its own retention capability through integrated latches, eliminating the need for separate adhesive materials and application processes, thereby reducing manufacturing costs.
3Reliability
If adhesive is applied for permanent retention, then component retention is achieved, but additional manufacturing steps are added
Solution Approach 1:
The patent extracts the retention function from the adhesive application process and integrates it into the insert design. This eliminates multiple manufacturing steps including adhesive application, curing, and inspection, thereby improving productivity.
Solution Approach 2:
The retention latches are pre-formed as integral parts of the insert during the molding process. This preliminary integration of the retention function eliminates the need for subsequent adhesive application steps, streamlining the manufacturing process.
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 design provides a robust, reliable, and cost-effective method for permanent component retention, enhancing mechanical and electrical connection reliability without the use of adhesives, while reducing manufacturing complexity and preventing unwanted component removal.
Implementation Method 1
The latches are positioned proximate to the contact-receiving openings thereby allowing the latches to deform into the contact-receiving openings
Data Source
Figure 1~2
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Figure 6~8
AI summary
An electrical connector (10) with an insert assembly (18, 20, 22) used to retain contacts (24) in the electrical connector (10). The insert assembly includes a rear insert (20) and a front insert (18). The rear insert (20) has a rear insert front surface (44), a rear insert rear surface (46) and a rear insert outer surface (50). The rear insert outer surface (50) extends between the rear insert front surface (44) and the rear insert rear surface (46). Rear insert contact-receiving openings (48) extend from the rear insert front surface (44) to the rear insert rear surface (46). Latches (54) are provided in the rear insert outer surface (50) and are provided in alignment with respective rear insert contact-receiving openings (48). The latches (54) are integrally formed in the rear insert outer surface (50). The latches (54) are positioned proximate to the rear insert contact-receiving openings (48) thereby allowing the latches (54) to deform into the rear insert contact-receiving openings (48).