Electrical Connector TPA Structure for Fewer Molds and Strong Retention
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Solution Overview
Problem
Existing electric connectors require multiple terminal position assurance (TPA) components of varying sizes and structures, increasing the number of molds needed for production and complicating assembly.
Innovation Solution
An electric connector design featuring a shell component with housing clamping arms and a TPA component that applies force to these arms to deform inward, ensuring terminal retention with reduced TPA components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple TPA components are mounted on the connector housing to achieve terminal position assurance, then the terminal retention reliability is improved, but the device complexity and number of molds required increases
Solution Approach 1:
The patent combines multiple TPA components into a single integrated TPA component that simultaneously engages with multiple housing clamping arms. This single component includes multiple pressing arms that can apply force to different housing clamping arms at the same time, reducing the total number of TPA components needed while maintaining terminal position assurance across multiple terminal channels
Solution Approach 2:
The single TPA component is designed to perform multiple functions by simultaneously providing terminal position assurance for multiple terminal channels. The component can engage with both first and second housing clamping arms, and can accommodate different terminal positions (e.g., six terminal positions) through its multi-armed structure, making it a universal solution that replaces multiple specialized TPA components
2Reliability
If multiple TPA components of different sizes and structures are used for the same connector, then the terminal position assurance is improved, but the manufacturing complexity increases due to increased number of molds
Solution Approach 1:
The patent consolidates multiple TPA components with different sizes and structures into a single standardized TPA component design. This unified component can be produced using a single mold, eliminating the need for multiple specialized molds while still providing the necessary terminal position assurance for all terminal channels through its integrated multi-armed structure
Solution Approach 2:
The universal TPA component design serves all terminal position assurance needs across different terminal channels without requiring component variations. The single component type can be manufactured in large quantities using one mold, improving manufacturing efficiency and reducing tooling costs while maintaining the ability to assure terminal positions throughout the connector
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 design achieves effective terminal position assurance with fewer components, simplifying manufacturing and assembly by reducing the number of molds required and enhancing retention force.
Implementation Method 1
each TPA component is to apply a force to both the first housing clamping arm and the second housing clamping arm, such that both the first housing clamping arm and the second housing clamping arm are deformed towards the inside of the plastic housing
Data Source
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AI summary
This application proposes an electric connector, comprising: a shell component comprising a plurality of terminal channels to contain terminals, wherein the shell component comprises a plastic housing formed with multiple housing clamping arms, said multiple housing clamping arms are corresponding to the plurality of terminal channels respectively, wherein the multiple housing clamping arms comprises a first housing clamping arm formed on left side and right side of the plastic housing, and a second housing clamping arm formed on upper side and lower side of the plastic housing; and a terminal position assurance TPA component to be mounted onto the left side and right side of the plastic housing of the shell component, wherein each TPA component is to apply a force to both the first housing clamping arm and the second housing clamping arm, such that both the first housing clamping arm and the second housing clamping arm are deformed towards the inside of the plastic housing.