Connector Terminal Stabilizer for Alignment Precision
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Solution Overview
Problem
Existing electrical connector assemblies face issues with improper alignment of terminals, leading to poor electrical connections, uneven cable seal compression, and potential damage during assembly and disassembly, due to lack of effective alignment and stabilization mechanisms.
Innovation Solution
The connector assembly incorporates a terminal-stabilizer feature with movable flexible locks and alignment rods, which ensures proper alignment and stabilization of electrical terminals, allowing for secure mating and safe disassembly by transitioning between locked and unlocked positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional electrical connector assemblies are used without terminal-stabilizer, then the device complexity is reduced, but the manufacturing precision and reliability of terminal alignment deteriorate
Solution Approach 1:
The terminal stabilizer acts as an intermediary component between the connector housing and the electrical terminals. It provides a stable reference structure that guides terminal insertion and maintains proper alignment, thereby improving manufacturing precision without requiring complex integrated alignment mechanisms in the housing itself.
Solution Approach 2:
The connector assembly is segmented into distinct functional components: the housing, the terminal stabilizer, and the electrical terminals. This segmentation allows the stabilizer to be optimized specifically for alignment functions while keeping the overall device complexity manageable through modular design.
2Reliability
If flexible locks are held in locked position during mating, then the terminal stabilization is improved, but the flexibility and ease of disassembly deteriorates
Solution Approach 1:
The flexible lock mechanism transitions between locked and unlocked states dynamically. During mating operations, the lock engages to stabilize terminals. During disassembly, the lock can be released to allow easy removal. This dynamic behavior resolves the contradiction between maintaining stability during operation and enabling ease of maintenance.
Solution Approach 2:
The flexible lock operates periodically - engaged during mating to provide stabilization, and disengaged during disassembly to provide ease of operation. This periodic engagement and disengagement allows the system to alternate between requiring high stability and requiring high operability.
3Manufacturing precision
If alignment rods are used for terminal alignment, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The alignment rods serve multiple functions: they guide terminal insertion, maintain proper spacing, and provide structural support within the connector housing. By making these simple rods multi-functional, the design achieves high alignment precision without adding numerous specialized components that would increase complexity.
Data Source
AI summary
A connector assembly includes a first-connector-housing, an inner-housing, a terminal-stabilizer, and a second-connector-housing. The inner-housing is disposed within a cavity defined by the first-connector-housing. The inner-housing includes an opposed flexible-lock moveable from a locked-position to an unlocked-position. The terminal-stabilizer is disposed within the cavity and is movable from a pre-stage-position to a seated-position. The terminal-stabilizer defines a stop configured to engage an end of the opposed flexible-lock when the opposed flexible-lock is in the locked-position. The second-connector-housing includes an unlocking-feature configured to move the opposed flexible-lock from the locked-position to the unlocked-position. When the second-connector-housing is mated with the first-connector-housing the unlocking-feature moves the opposed flexible-lock to the unlocked-position, whereby the stop on the terminal-stabilizer moves past the opposed flexible-lock and the second-connector-housing moves the terminal-stabilizer from the pre-stage-position to the seated-position.