Connector Position Assurance Device for Secure Mating
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Solution Overview
Problem
Existing electrical connector assemblies face challenges in ensuring proper mating and securing of connectors, especially in small sizes, due to noise interference and space constraints, leading to system failures and improper engagement.
Innovation Solution
An electrical connector assembly with a compact connector position assurance device that includes a U-shaped connector position assurance member with parallel beams and a press bar, which is moved from an initial to a locked position upon full mating, ensuring secure engagement and preventing unintended disengagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an audible click is used to detect proper connector mating, then the operator can detect if the connector is fully mated, but noise at the assembly plant makes this detection ineffective
Solution Approach 1:
The patent replaces the acoustic detection method (audible click) with a visual detection method using a movable indicator member that changes position based on connector engagement status. The indicator provides visual feedback through its position rather than acoustic feedback, eliminating the problem of noise interference at the assembly plant while maintaining accurate detection of proper connector mating.
2Reliability
If a known connector position assurance device is used to ensure proper connector mating, then connector engagement can be verified, but the device requires significant space that is not available in small connectors
Solution Approach 1:
The patent integrates the indicator member within the existing connector housing structure, nesting it inside the connector assembly rather than adding it as an external component. The indicator member is positioned to move within the connector's internal space, allowing verification of proper engagement without increasing the overall connector volume, thus solving the space constraint problem in small connectors.
3Reliability
If operators manually activate connector position assurance features, then connector mating can be verified, but operators often do not properly activate these features leading to improper mating
Solution Approach 1:
The patent designs the indicator member to automatically move and indicate connector engagement status without requiring operator activation. The indicator is mechanically coupled to the connector components so that it self-actuates based on the engagement state, eliminating the need for operators to manually activate position assurance features and ensuring reliable verification of proper mating.
4Volume of moving object
If connectors are designed for small size to meet application requirements, then space is saved, but there is insufficient space for effective connector position assurance mechanisms
Solution Approach 1:
The patent combines the position assurance function with the existing connector structure by integrating the indicator member into the connector housing. The indicator leverages the mechanical movement of existing connector components (such as the housing or internal parts) to provide position verification, merging multiple functions into a compact design that maintains reliability while preserving small connector size.
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 provides reliable and secure connector mating assurance for small-sized connectors, reducing system failures by ensuring proper engagement and locking, even in noisy environments, and preventing connectors from coming apart during use.
Implementation Method 1
a resilient beam, the leading end of which is engaged with a stop member of the connector
Data Source
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AI summary
A connector position assurance device (1000), an electrical connector and an electrical connector assembly which provides proper connector position assurance of a connector assembly of small size. The connector position assurance device has a base portion (1003), a first beam (1002) and a second beam. The first and second beams extend from the base portion. The base portion includes a latch engagement protrusion (1010). A first beam has a first connector engagement protrusion (1016) and a second beam has a second connector engagement protrusion (1016). The first and second connector engagement protrusions are resiliently actuated as the plug is mated to the header. The first and second connector engagement protrusions and the latch engagement protrusion cooperate with the plug when the plug is fully mated to the header to prevent the inadvertent removal of the plug from the header.