Connector Position Assurance via Flexible Beam Inclined Surfaces
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Solution Overview
Problem
Existing connector assemblies, especially unsealed ones, fail to effectively manage vibration in higher vibration environments, leading to relative motion between terminals that causes intermittent connections and fretting corrosion, and they lack precise longitudinal alignment, which is critical in miniaturized connectors.
Innovation Solution
A connector assembly design featuring a first connector body with a longitudinally-oriented flexible beam and a second connector body with a cavity, where the flexible beam's inclined surfaces engage to generate a longitudinal force when a member is inserted, ensuring a tight fit and reducing vibration, while also providing precise longitudinal positioning through inclined surfaces and a connector position assurance device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If unsealed connector assemblies are used to reduce cost, then manufacturing cost is reduced, but they cannot withstand higher vibration environments leading to relative motion between terminals
Solution Approach 1:
The connector assembly is divided into sealed and unsealed portions, with the sealed portion containing the vibration-resistant mechanism (flexible beam with inclined surfaces) and the unsealed portion providing cost benefits. This segmentation allows the expensive vibration-resistant features to be applied only where necessary rather than the entire connector assembly
Solution Approach 2:
The flexible beam's inclined surfaces are designed with specific geometric parameters (angles, dimensions) that enable vibration damping through mechanical interaction. By optimizing these parameters, the connector achieves vibration resistance in an unsealed configuration, reducing the need for complete sealing while maintaining reliability
2Volume of moving object
If connector assemblies are miniaturized to reduce size, then compactness is improved, but longitudinal alignment between terminals becomes more critical and difficult to maintain
Solution Approach 1:
The flexible beam with inclined surfaces performs preliminary alignment action during the insertion process itself. As the connector body is inserted, the inclined surfaces automatically guide and position the terminals longitudinally before final engagement, ensuring precise alignment without requiring post-assembly adjustments or complex precision machining
Solution Approach 2:
The flexible beam provides dynamic alignment compensation that adapts to manufacturing tolerances and assembly variations. The beam's flexibility allows it to deform and accommodate minor misalignments while the inclined surfaces maintain precise longitudinal positioning, enabling accurate terminal alignment in miniaturized connectors despite variations in manufacturing
3Reliability
If compliant seals are added to reduce relative motion from vibration, then vibration resistance is improved, but manufacturing cost increases
Solution Approach 1:
The sealing function is extracted from the vibration-resistant mechanism. Instead of using compliant seals to achieve vibration resistance, the patent uses a separate mechanical mechanism (flexible beam with inclined surfaces) that provides vibration damping without requiring sealing components. This extraction allows vibration resistance to be achieved in an unsealed, lower-cost configuration
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 reduces relative vibration and ensures precise longitudinal alignment between terminals, enhancing the reliability and performance of connectors in high-vibration environments, such as automotive applications, by generating a longitudinal force that secures the connectors and terminals in intimate contact.
Implementation Method 1
The flexible beam is flexible and is configured to flex laterally in response to an insertion force applied to the first connector body in the longitudinal direction
Implementation Method 2
The lateral movement of the flexible beam causes the inclined surfaces to move relative to each other, thereby generating a force in the longitudinal direction
Data Source
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AI summary
A connector assembly (10) includes a first connector body (22) defining a channel (32) between a longitudinally-oriented fixed wall and a longitudinally-oriented flexible beam (38). The flexible beam (38) is located opposite and generally parallel to the fixed wall when in a relaxed state. A distal surface (46) of the flexible beam (38) defines a first protrusion (48) having a first inclined surface (50). A second connector body (52) defines a cavity (56) configured to receive the first connector body (22). A mesial surface (58) inside the cavity (56) defines a second protrusion (60) having a second inclined surface (62) configured to engage the first inclined surface (50) of the flexible beam (38) when the connector bodies (22, 52) are mated. A member (64) inserted into the channel (32) causes the flexible beam (38) to flex laterally and move the first inclined surface (50) with respect to the second inclined surface (62) sufficient to generate a longitudinal force (F) between the first and second inclined surfaces (50, 62) and thus between the first and second connector bodies (22, 52).