Connector Resistor-Assembly Retention via Spring-Terminals
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connectors lack effective solutions to securely retain resistors and electrical terminals within a housing, especially under vibrations and shock loads, which can lead to unintentional removal and disruption of electrical continuity.
Innovation Solution
A resistor-assembly is integrated within a terminal-position-assurance device (TPA) using spring-terminals and a resistor, where the resistor is securely positioned between the spring-terminals and retained within a cavity, with connection-leads press-fit or metallurgically bonded to ensure stability and prevent movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resistors and electrical terminals are retained using conventional methods in electrical connectors, then the device complexity is reduced, but the reliability deteriorates due to unintentional removal under vibrations and shock loads
Solution Approach 1:
The resistor-assembly is nested within the terminal-position-assurance device, which itself is positioned within the housing. This nested structure allows the resistor to be retained within the TPA cavity while the TPA device provides additional retention through its engagement with the housing, creating a multi-layered retention system that prevents unintentional removal under vibrations and shock loads without requiring a completely new connector design
Solution Approach 2:
The spring-terminals are pre-configured with biasing force to engage the resistor leads before any vibration or shock occurs. This preliminary engagement ensures that the resistor is securely held in position from the outset, preventing movement and potential removal before harmful vibrations or shocks can occur
2Reliability
If spring-terminals with biasing force are used to retain the resistor, then the reliability improves through secure retention, but the device complexity increases due to additional components
Solution Approach 1:
The function of retaining the resistor and maintaining electrical continuity is merged into a single integrated structure where the spring-terminals serve both as electrical contacts and as retention mechanisms. The TPA device combines the resistor retention function with the terminal positioning function, eliminating the need for separate retention mechanisms and reducing overall complexity
Solution Approach 2:
The spring-terminals are designed to perform multiple functions simultaneously: they provide electrical connection, apply retention force through biasing, and maintain positional stability. The TPA device serves both as a resistor retention mechanism and as a terminal position assurance device, reducing the need for separate components
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 a secure retention of the resistor-assembly, maintaining electrical continuity and preventing unintentional removal by applying a balanced spring-force and engagement-force, ensuring reliability under operational conditions.
Implementation Method 1
a first-spring-terminal (22) and a second-spring-terminal (24) in separate electrical-communication with at least one of the plurality of electrical-terminals (14)... applying a balanced spring-force and engagement-force
Data Source
AI summary
A connector-assembly includes a housing, a terminal-position-assurance device, and a resistor-assembly. The housing includes a plurality of electrical-terminals. The terminal-position-assurance device is configured to retain the plurality of electrical-terminals within the housing. The resistor-assembly is disposed within the terminal-position-assurance device and includes a first-spring-terminal, a second-spring-terminal, and a resistor disposed between the first-spring-terminal and the second-spring-terminal. The first-spring-terminal and the second-spring-terminal are in separate electrical-communication with at least one of the plurality of electrical-terminals. The resistor has connection-leads disposed within slots formed in both the first-spring-terminal and the second-spring-terminal, and is disposed within channels formed in the terminal-position-assurance device. The first-spring-terminal, the second-spring-terminal, and the terminal-position-assurance device are in compressive contact with a portion of the connection-leads.