Connector Terminal Position Assurance for Tool-Free Service

Solution Overview

Problem

Conventional electrical connectors require a service tool to disconnect and remove electrical terminals from their housings for maintenance or service, which is inconvenient.

Innovation Solution

An improved electrical connector design featuring a housing with a retaining finger and terminal position assurance that allows the electrical terminal to be removed without a service tool, utilizing a movable terminal position assurance between pre-lock, service, and lock positions to facilitate easy removal and reinstallation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a service tool is required to disconnect the electrical terminal from the housing, then the terminal can be securely retained, but the ease of operation deteriorates due to the need for external tools

Engineering Contradiction:

Improveterminal retention securityVSAvoidterminal removal convenience

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The terminal position assurance is designed to be manually movable between locked and unlocked positions without requiring external service tools. The component itself provides the mechanism for its own release, allowing the terminal to be removed by simply moving the position assurance to the unlocked position, thus making the system self-servicing.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The terminal position assurance transitions between fixed (locked) and movable (unlocked) states. When in the locked position, it prevents terminal withdrawal; when moved to the unlocked position, it allows terminal removal. This dynamic state change enables secure retention during operation while facilitating easy removal when needed.

Inventive Principle:

Principle #15Dynamics

2Ease of operation

If the electrical terminal is easily removable without tools, then the ease of operation improves, but the device complexity increases due to the movable terminal position assurance mechanism

Engineering Contradiction:

Improveterminal removal convenienceVSAvoidconnector structure complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The terminal position assurance serves multiple functions: it locks the terminal in position during normal operation, provides a visible indicator of the locked state, and enables tool-free release when moved to the unlocked position. By consolidating these functions into a single component, the design adds minimal complexity while achieving multiple goals.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The connector is divided into distinct functional components: the housing, the terminal, and the terminal position assurance. This segmentation allows each component to be optimized independently and facilitates easy assembly and disassembly, reducing overall system complexity while improving serviceability.

Inventive Principle:

Principle #1Segmentation

3Reliability

If the terminal position assurance is always locked, then the terminal retention security is maintained, but the ease of repair deteriorates due to inability to remove terminal for service

Engineering Contradiction:

Improveterminal retention securityVSAvoidterminal serviceability

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The terminal position assurance transitions between fixed (locked) and movable (unlocked) states. When in the locked position, it prevents terminal withdrawal; when moved to the unlocked position, it allows terminal removal. This dynamic state change enables secure retention during operation while facilitating easy removal when needed.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The terminal position assurance is designed to be manually movable between locked and unlocked positions without requiring external service tools. The component itself provides the mechanism for its own release, allowing the terminal to be removed by simply moving the position assurance to the unlocked position, thus making the system self-servicing.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS10826220B1Electrical connector having electrical terminal servicing feature

Publication Date: 2020.11.03 LEAR CORP

AI summary

An electrical connector includes a housing having an interior space and a retaining finger extending into the interior space. An electrical terminal and a terminal position assurance are each disposed within the interior space of the housing. The terminal position assurance is movable relative to the housing between (1) a pre-lock position, wherein the retaining finger prevents the electrical terminal from being withdrawn from the interior space of the housing, and the terminal position assurance does not prevent the retaining finger from moving relative to the housing; (2) a service position, wherein the retaining finger does not prevent the electrical terminal from being withdrawn from the interior space of the housing; and (3) a lock position, wherein the retaining finger prevents the electrical terminal from being withdrawn from the interior space of the housing, and the terminal position assurance prevents the retaining finger from moving relative to the housing.