Electrical Connector Terminal Locking for Strength and Insertion Force
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Solution Overview
Problem
Existing electrical connector assemblies for automotive wiring harnesses face issues with terminal retention, where lock nibs made of unreinforced thermoplastics are sheared off by terminal forces, and those made of glass fiber reinforced thermoplastics have stiff flexible cantilever beams that fail to provide an acceptable insertion force.
Innovation Solution
The electrical connector assembly incorporates a terminal retainer with a flexible terminal lock arm and a moveable terminal lock nib that engages a pair of retaining ridges on the electrical terminal, providing enhanced retention and insertion force while preventing removal through either opening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lock nibs are made of unreinforced thermoplastics, then ease of manufacture is improved, but strength deteriorates (lock nibs are sheared off by terminal forces)
Solution Approach 1:
The patent employs glass fiber reinforced thermoplastic material for the lock nibs, combining the ease of thermoplastic manufacturing with enhanced strength and stiffness from glass fiber reinforcement. This composite material approach resolves the contradiction by maintaining manufacturability while achieving the required mechanical strength to resist terminal forces without shearing.
2Strength
If lock nibs are made of glass fiber reinforced thermoplastics, then strength is improved, but flexibility deteriorates (cantilever beams are too stiff to provide acceptable insertion force)
Solution Approach 1:
The patent divides the locking mechanism into two distinct functional segments: rigid lock nibs made of glass fiber reinforced thermoplastic for strength and retention, and flexible cantilever beams made of elastomeric material for insertion. This segmentation allows each component to be optimized for its specific function, resolving the contradiction between strength and flexibility.
Solution Approach 2:
The patent applies different material properties to different parts of the connector body: the lock nibs use glass fiber reinforced thermoplastic for high strength, while the cantilever beams use elastomeric material for flexibility. This local differentiation of material quality enables each region to possess the specific properties needed for its function, simultaneously achieving strength and ease of operation.
3Strength
If a single rigid lock nib structure is used, then strength is improved, but adaptability deteriorates (cannot provide both retention force and insertion force)
Solution Approach 1:
The patent introduces dynamic characteristics to the locking mechanism through the flexible cantilever beams that can deflect during insertion and then spring back to engage the lock nibs. This dynamic behavior allows the system to adapt to the insertion process while maintaining strong retention once engaged, resolving the contradiction between strength and adaptability.
Solution Approach 2:
The patent creates a multi-functional locking system where the rigid lock nibs provide retention strength while the flexible cantilever beams provide both insertion assistance and sealing functions. This universal design allows a single connector body to perform multiple functions (retention, insertion, sealing) that would otherwise require separate components, achieving both strength and adaptability.
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
This solution effectively inhibits terminal removal through both openings, ensuring secure retention and compliant sealing, thereby addressing the limitations of existing connector assemblies.
Implementation Method 1
a flexible terminal lock arm having a moveable terminal lock nib that projects inwardly into the terminal cavity from the flexible terminal lock arm
Implementation Method 2
a flexible retaining arm. The terminal retainer further includes a flexible terminal lock arm
Data Source
AI summary
An electrical connector assembly includes an electrical terminal defining a pair of retaining ridges, a connector housing having a terminal cavity extending therethrough from a first opening to a second opening and a fixed terminal lock nib that projects inwardly into the terminal cavity from a rigid first wall to engage a first ridge of the pair of retaining ridges of the electrical terminal, and a terminal retainer inserted within the connector housing proximate the first opening and removably retained to the connector housing by a flexible retaining arm. The terminal retainer further includes a flexible terminal lock arm having a moveable terminal lock nib that projects inwardly into the terminal cavity from the flexible terminal lock arm to engage a second ridge of the pair of retaining ridges of the electrical terminal, thereby inhibiting removal of the electrical terminal from the terminal cavity through the second opening.