Connector Assembly Primary Lock Reinforcement Device
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Solution Overview
Problem
Existing electrical connector assemblies fail to maintain component position during shipping and handling, leading to inadvertent and premature movement, which can result in incorrect assembly and unseated terminals.
Innovation Solution
A primary lock reinforcement device (PLR device) is introduced, which is a moveable component that engages a terminal tower and includes a flexible beam with a tip that locks into a stop, preventing movement until terminals are fully seated, requiring a specific force to transition from a prestaged to a full staged position, thereby ensuring proper seating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a primary lock reinforcement device is added to prevent premature movement, then component position stability is improved, but device complexity increases
Solution Approach 1:
The connector assembly is divided into distinct functional components: a housing, a terminal tower, and a separate primary lock reinforcement device. This segmentation allows each component to perform its specific function independently while maintaining overall system stability, resolving the contradiction by adding a dedicated stabilization component rather than complicating existing structures.
Solution Approach 2:
The primary lock reinforcement device is designed to engage with the terminal tower in advance, establishing a predetermined locking configuration before terminals are inserted. This preliminary action prevents premature movement during assembly, ensuring component position stability is established before the assembly process begins, thereby improving stability without requiring complex real-time control mechanisms.
2Reliability
If a flexible beam with tip engagement is used to prevent premature movement, then reliability of terminal seating is improved, but manufacturing precision requirements increase
Solution Approach 1:
The primary lock reinforcement device incorporates a flexible beam that can dynamically adjust its position. The beam transitions from an engaged state with the stop to a disengaged state as terminals are fully seated, providing reliable terminal seating confirmation through its movement. This dynamic mechanism reduces manufacturing precision requirements compared to rigid locking structures, as the flexibility accommodates normal dimensional variations while maintaining functional reliability.
3Ease of operation
If a force requirement is implemented to transition from prestaged to full staged position, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The primary lock reinforcement device is pre-configured in a prestaged position where the flexible beam engages the stop, establishing a predetermined locked state before assembly operations begin. This preliminary positioning provides clear operational feedback and simplifies the assembly process, as operators can easily recognize when terminals are properly seated by observing the device transition to its full staged position, thereby improving ease of operation without requiring complex control systems.
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 PLR device effectively prevents premature movement of components during assembly, ensuring terminals are fully seated before allowing the device to move to its full staged position, thus alerting assemblers to any unseated conditions and ensuring correct assembly by requiring a distinct force to transition states.
Implementation Method 1
a flexible beam with a tip that locks into a stop, preventing movement until terminals are fully seated, requiring a specific force to transition from a prestaged to a full staged position
Data Source
AI summary
A connector assembly includes electrical terminals, a connector housing, and a primary lock reinforcement device. The electrical terminals are configured to mate with corresponding electrical terminals along a mating axis of the connector assembly. The connector housing is configured to retain the electrical terminals within terminal cavities defined by a terminal tower disposed within the connector housing. The primary lock reinforcement device is configured to slideably engage the terminal tower and is moveable from a prestaged position to a full staged position. The primary lock reinforcement device has a base and a skirt defining a cavity having a flexible beam disposed within and terminating at a tip. The tip engages a stop in the connector housing in the prestaged position inhibiting a movement of the primary lock reinforcement device along the mating axis. When the electrical terminals are fully seated into the terminal cavities, the electrical terminals disengage the tip from the stop enabling the primary lock reinforcement device to move from the prestaged position to the full staged position.