Connector Cover Rail Retention Without Position Assurance Locks

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Solution Overview

Problem

Current connector assemblies for vehicles require position assurance locks to secure terminal-receiving bodies relative to connector bodies, leading to inefficiencies in the assembly process.

Innovation Solution

A connector assembly system that includes a connector body with a rim and a cover with a shoulder and rail, where the cover is removably coupled to the connector body, and the rail engages the terminal housing to secure it within the cavity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If position assurance locks are used to secure terminal-receiving bodies relative to connector bodies, then alignment and position security are improved, but assembly efficiency and process simplicity deteriorate

Engineering Contradiction:

Improvealignment precisionVSAvoidassembly efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent removes the separate position assurance lock component from the connector assembly. Instead of using a distinct locking mechanism, the terminal-receiving body itself is designed with features (such as positioning protrusions or shaped structures) that directly engage with the connector body to maintain proper alignment and position, thereby eliminating the need for additional locking parts and simplifying the assembly process

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent integrates the positioning function directly into the terminal-receiving body structure. The terminal-receiving body is designed to combine both its primary function (receiving and securing terminals) and its positioning function (maintaining alignment with the connector body) within a single integrated component, eliminating the need for separate positioning mechanisms

Inventive Principle:

Principle #5Merging (Combining)

2Stability of the object's composition

If position assurance locks are used to secure terminal-receiving bodies, then position stability is improved, but device complexity increases

Engineering Contradiction:

Improveposition stabilityVSAvoidconnector assembly complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent eliminates the separate position assurance lock component from the connector assembly. Instead of using a distinct locking mechanism, the terminal-receiving body itself is designed with features (such as positioning protrusions or shaped structures) that directly engage with the connector body to maintain proper alignment and position, thereby eliminating the need for additional locking parts and simplifying the assembly process

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20250167477A1Connector Assembly and Related Methods

Publication Date: 2025.05.22 APTIV TECHNOLOGIES AG

AI summary

A connector assembly includes a connector body defining a cavity and having a rim extending around the cavity. The connector assembly includes a terminal housing removably-disposed within the cavity. The connector assembly includes a cover removably-coupled to the connector body. The cover includes a shoulder and a rail disposed adjacent to the shoulder. In an assembled orientation, the shoulder is configured to engage the rim, and the rail is disposed within the cavity and is configured to engage the terminal housing to secure the terminal housing within the cavity.