Electrical Connector Locking Arms With Wedging Retention
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Solution Overview
Problem
Electrical connector assemblies face issues with axial variation affecting terminal-to-terminal contact overlap and low retention force due to unreinforced flexible locking arms, while laterally loaded terminal modules increase package size.
Innovation Solution
The connector assembly incorporates cantilevered locking arms with primary and secondary surfaces, where secondary surfaces are angled to provide a wedging interface, enhancing retention force and reducing clearance, allowing for improved terminal overlap and compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If terminal modules are axially loaded into the outer connector housing, then the assembly process is simplified, but the clearance between the locking arm and terminal module frame increases, affecting terminal-to-terminal contact overlap
Solution Approach 1:
The stop face of the locking arm is divided into two distinct surfaces: a first surface for initial engagement and a second surface for final positioning. This segmentation allows the locking arm to perform two functions in sequence - first providing structural support during axial loading, then achieving precise terminal alignment, thereby resolving the contradiction between simplified assembly and manufacturing precision
Solution Approach 2:
The first surface of the locking arm engages the terminal module frame early in the assembly process to provide preliminary support and alignment. This preliminary engagement enables the simplified axial loading process while the subsequent engagement of the second surface ensures the required terminal-to-terminal contact overlap precision
2Device complexity
If flexible locking arms are used without reinforcement, then the device complexity is reduced, but the retention force between the inner terminal module frame and outer connector housing becomes low
Solution Approach 1:
The locking arm structure utilizes the header connector body itself as a reinforcement element. When the header is inserted, its body engages with and reinforces the locking arm, creating a self-reinforcing mechanism that increases retention force without adding external reinforcement components, thus maintaining low device complexity while improving force
3Manufacturing precision
If terminal modules are laterally loaded into the outer connector housing, then the terminal-to-terminal contact overlap is improved, but the overall package size increases
Solution Approach 1:
Instead of laterally loading the terminal modules to achieve proper overlap, the invention inverts the approach by using axial loading combined with the two-surface locking mechanism. The locking arm's second surface provides the necessary lateral positioning and overlap adjustment after axial insertion, achieving the same precision result with a more compact package size
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 solution achieves reduced package size, enhanced terminal overlap, and improved retention force through the use of angled secondary surfaces and wedging interfaces, ensuring stable electrical connections.
Implementation Method 1
the secondary surfaces are angled and configured to provide the second force on the latch surfaces due to a wedging interface between the secondary surfaces and edges of the latch surfaces
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
An electrical connector assembly (100) configured to contain electrical terminals (306) connected to one or more electrical cables (308), an inner module frame (302) in which terminal modules (304) are secured, and an outer housing (106) having cantilevered locking arms (502) with primary surfaces (508) and secondary surfaces (510) on inner sides of the locking arms (502) to secure the inner module frame (302) to the female outer housing (106). Latch surfaces (904) of the inner module frame (302) engage the primary surfaces when the inner module frame (302) is inserted within the female outer housing (106). The female outer housing (106) receives a header having side walls (404) surrounding mating electrical terminals (406). The locking arms (502) define ramp features on outer sides of the locking arms (502) that push the locking arms (502) inwardly when the side walls (404) contact the ramp features of the locking arms (502) as the header is inserted within the outer housing (106). A method (1900) of assembling such an electrical connector (100) is also provided.