Connector Primary Lock Reinforcement via Wedging Actuator
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Solution Overview
Problem
Existing electrical connectors face issues with primary lock reinforcement and terminal position assurance, particularly in high vibration or large current load environments, where primary lock components fail to retain or align terminals properly, leading to unstable electrical interconnections.
Innovation Solution
The electrical connector assembly incorporates a primary lock reinforcement (PLR) system with a blocking projection that is constrained to move laterally, allowing for wedging action by a PLR actuator to reinforce the primary lock against deflection, ensuring proper terminal positioning and secure mating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a primary lock structure is used to retain terminals, then terminal retention is improved, but the primary lock fails under high vibration or large current load conditions
Solution Approach 1:
The patent applies preliminary action by pre-positioning the blocking projection in a retracted state before assembly, which then moves into the locked position during the assembly process. This ensures the primary lock is reinforced exactly when needed during terminal insertion, preventing failure under high vibration or current load conditions while maintaining terminal retention.
Solution Approach 2:
The patent segments the locking function into two independent components: the primary lock structure for initial terminal retention and the blocking projection for reinforcement. This segmentation allows each component to be optimized independently - the primary lock for basic retention and the blocking projection for additional strength under harsh conditions.
2Manufacturing precision
If insertion forces are applied during assembly, then terminal positioning is achieved, but the primary lock components fail under relatively high insertion forces
Solution Approach 1:
The blocking projection is pre-positioned in a retracted state that allows free terminal insertion, then automatically moves into the reinforced locked position as the assembly progresses. This preliminary positioning ensures high manufacturing precision during terminal placement while preventing component failure under the high insertion forces encountered during assembly.
Solution Approach 2:
The blocking projection is designed to be movable rather than fixed, transitioning dynamically from a retracted position during assembly to a locked position after assembly. This dynamic behavior allows the system to accommodate high insertion forces during terminal positioning while providing reinforcement to prevent failure under normal operating conditions.
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 maintains terminal position and prevents assembly defects by reinforcing the primary lock against deflection, ensuring stable electrical connections even under high load conditions and vibrations.
Implementation Method 1
A PLR actuator is carried by a second housing and engages and moves the PLR device in the lateral direction between pre- and fully-staged configurations. The PLR actuator includes an elongated finger providing a wedging action to move the PLR device as the housings are brought together.
Data Source
AI summary
A connector assembly comprises a resilient primary lock for securing a wire terminal with a housing, a primary lock reinforcement (PLR) device, and a PLR actuator for moving the PLR device between pre- and fully-staged configurations. The PLR device is configured to move in response to contact by the PLR actuator as the housing components are mated together. The PLR actuator includes an elongated, tapered finger that wedges against the PLR device during housing mating. A method of reinforcing a primary lock of a connector assembly is also described.