Connector Asymmetric Tapered Locking Hole Offset Alignment
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Solution Overview
Problem
Existing connector locking structures face difficulties in aligning rectangular or regularly shaped terminals and housings due to potential offsets, leading to locking issues and material constraints during terminal manufacturing, especially when bending semi-finished terminals.
Innovation Solution
A connector design featuring a terminal with a locking hole and a latch, where the locking hole and latch sizes gradually increase in the insertion direction, allowing for smooth alignment and locking despite offsets, and optimizing material usage by positioning the locking hole further from the bend line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If rectangular or regular shaped locking hole and latch are used, then the locking structure is simple to manufacture, but alignment between terminal and housing becomes difficult when offset occurs
Solution Approach 1:
The locking hole and latch are designed with asymmetric tapered geometry where the opening end has a larger cross-sectional area than the bottom end. This asymmetric design allows the latch to smoothly enter the locking hole even when offset occurs during insertion, while maintaining manufacturing simplicity. The tapered shape provides self-aligning characteristics that resolve the contradiction between ease of manufacture and locking reliability under offset conditions.
2Device complexity
If rectangular locking hole is used, then the locking structure is easy to design, but material availability for bending is reduced when bend line is close to the hole
Solution Approach 1:
The locking hole is designed with a tapered curved geometry rather than a rectangular shape. This curved design reduces the material occupation area compared to a rectangular hole of equivalent functional size, leaving more material available for the bend line. The curved shape maintains design simplicity while improving bending feasibility by preserving sufficient material in the critical bending region.
3Ease of manufacture
If regular shaped latch and locking hole are used, then the structure is symmetric and easy to manufacture, but the latch cannot protrude into the hole when offset occurs
Solution Approach 1:
Both the latch and locking hole are designed with asymmetric tapered geometry where the opening end is larger than the bottom end. This asymmetric design enables smooth insertion and reliable locking even when offset occurs, while remaining compatible with standard manufacturing processes. The tapered shape provides guiding characteristics that facilitate easy operation during insertion.
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
Ensures reliable locking and reduces material constraints during terminal manufacturing by accommodating slight offsets and preserving material for bending, enhancing the manufacturing process.
Implementation Method 1
The latch elastically protrudes into the locking hole to lock the terminal in the housing
Data Source
AI summary
A connector includes a housing having a latch and a terminal mounted in the housing. The terminal has a locking hole with a locking hole front portion in a terminal insertion direction along which the terminal is inserted into the housing and a locking hole rear portion in the terminal insertion direction. A size of the locking hole front portion is larger than a size of the locking hole rear portion. The latch elastically protrudes into the locking hole to lock the terminal in the housing. The latch has a latch front portion in the terminal insertion direction and a latch rear portion in the terminal insertion direction. A size of the latch front portion is larger than a size of the latch rear portion. The size of the latch rear portion is smaller than the size of the locking hole front portion.