Connector Position Assurance Device Lateral Flange Mechanism
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Solution Overview
Problem
Existing electrical connector assemblies face difficulties in ensuring that the connector position assurance (CPA) device remains in its initial position until the connectors are fully mated, as the secondary latch can be forced under the primary latch prematurely, leading to incorrect connection.
Innovation Solution
A connector assembly design featuring a primary locking lever with a beam and a CPA device with a mobile base and lever, where the CPA lever defines a secondary latch that engages the primary latch, and a lateral flange that inhibits movement to the final position until the connectors are fully mated, ensuring secure locking and preventing premature disengagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the secondary latch is designed to engage the primary latch, then the CPA device can prevent disengagement of the primary latch and striker, but the secondary latch can be forced under the primary latch before connectors are fully mated, leading to incorrect connection
Solution Approach 1:
The patent introduces a lateral flange that extends perpendicular to the mating axis, creating a new dimensional constraint. This lateral flange engages with a corresponding feature on the mating connector to prevent the CPA device from moving laterally or prematurely engaging, thus solving the problem of incorrect connection while maintaining locking reliability
Solution Approach 2:
The lateral flange acts as an intermediary element between the CPA device and the mating connector. It mediates the engagement process by providing a preliminary mechanical constraint that prevents premature movement of the CPA device, ensuring that the secondary latch only engages the primary latch after proper alignment is achieved
2Reliability
If the CPA device is allowed to move to the final position only when connectors are fully mated, then correct connection is ensured, but the device complexity increases due to additional constraints and components
Solution Approach 1:
The patent combines the lateral positioning function and the locking function into a single integrated CPA device structure. The lateral flange and the secondary latch are part of the same CPA device, eliminating the need for separate positioning and locking mechanisms, thus reducing overall device complexity while maintaining connection accuracy
Solution Approach 2:
The CPA device is designed to perform multiple functions: it provides lateral positioning through the lateral flange, prevents premature engagement, and ensures proper locking through the secondary latch. This multi-functional design reduces the number of separate components needed, thereby reducing device complexity while ensuring connection accuracy
Data Source
Figure 1~2
Figure 3~4
Figure 5~5A
AI summary
A connector assembly (10) including a first connector (12) having a primary locking lever (20) that is configured to mate with a second connector (18) having a primary striker (48). The primary locking lever (20) includes a beam extending along a mating axis (X) and a primary latch (28) configured to engage the primary striker (48). The connector assembly (10) includes a connector position assurance (CPA) device (36) slideably mounted to the first connector (12). The primary latch (28) blochs movement of the CPA device (36) from an initial position (38) to a final position (40) until the first connector (12) and the second connector (18) are fully mated. The CPA device (36) defines a lateral flange that inhibits movement of a secondary latch (46) of the CPA device (36) under the primary latch (28) that would allow the CPA device (36) to move from the initial position (38) prior to the full mating of the first connector (12) and the second connector (18).