Electrical Contact Anti-Rotation Stabilizing Portion
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Solution Overview
Problem
Electrical connectors face issues with unwanted rotation and float of contacts within the housing, which can lead to improper mating and alignment problems, especially when excessive movement occurs.
Innovation Solution
Incorporating a stabilizing portion on the contact that extends from the contact portion and cooperates with stabilization members in the housing to minimize rotation, combined with a terminal position assurance device to increase the pull-out strength and prevent inadvertent removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the contact is designed without press fit structure, then the contact can more easily mate with mating contacts, but the contact experiences excessive float and rotation relative to the housing
Solution Approach 1:
The contact is divided into distinct functional segments: a contact portion for mating and a stabilizing portion for positioning. The stabilizing portion includes features like lugs or tabs that extend laterally to engage with corresponding features in the housing, separating the mating function from the stabilization function while both are integrated into a single contact component.
Solution Approach 2:
The stabilizing portion acts as an intermediary element between the contact portion and the housing. It provides a mechanical interface that transfers positioning forces from the housing to the contact, preventing rotation and float while allowing the contact portion to maintain its press-fitless design for easy mating.
2Adaptability or versatility
If the contact allows movement in the housing, then the contact can more easily align with mating contacts, but excessive movement causes the contact to stub on mating contacts and prevents proper mating
Solution Approach 1:
Different parts of the contact have different mobility characteristics. The contact portion is designed to allow minimal movement for alignment adaptability, while the stabilizing portion is designed to restrict movement to specific degrees. The stabilizing portion may allow limited lateral movement for alignment but prevents rotation through engagement features like lugs engaging with slots or grooves in the housing.
3Manufacturing precision
If the contact is designed with precise alignment control, then the contact alignment is precisely controlled, but the contact structure becomes more complex
Solution Approach 1:
The stabilizing portion incorporates asymmetric features such as lugs or tabs positioned at specific locations and orientations. These asymmetric elements engage with corresponding asymmetric features in the housing to define a unique rotational position, preventing rotation without requiring complex symmetric constraint mechanisms.
Data Source
AI summary
An electrical contact, connector and assembly. The contact includes a contact portion for mating with a mating contact. A stabilizing portion extends from an end of the contact which is opposite the contact portion. The stabilizing portion cooperates with at least one stabilization member of a housing of an electrical connector to minimize the rotation of the contact relative to the electrical connector. The connector includes a housing having stabilization members provided in contact receiving cavities. The assembly includes a terminal position assurance device which engages the stabilizing portions and cooperates with the stabilizing portions to increase the pull out force required to displace the contacts.