CPA Connector Locking for Vibration-Resistant Mating
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Solution Overview
Problem
Existing electrical connector systems face issues with vibrations and mechanical loads causing relative movement and wear between connector housings, leading to potential malfunctions and signal interruptions due to manufacturing tolerances and lack of secure locking mechanisms.
Innovation Solution
The integration of a Connector Position Assurance (CPA) element with a tapered shape that tensions the locking features of the connector housings, ensuring secure and accurate connection, and compensating for manufacturing tolerances to prevent relative movement and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If direct locking features are used to connect connector housings, then the locking mechanism is simple, but free spaces due to manufacturing tolerances allow relative movement under vibrations and mechanical loads
Solution Approach 1:
A CPA element is introduced as an intermediary component between the two connector housings. This element fills the free spaces created by manufacturing tolerances and prevents relative movement between the locked connector housings, thereby eliminating the harmful effect of vibrations and mechanical loads without complicating the basic locking mechanism
Solution Approach 2:
The connection system is segmented into three distinct components: the first connector housing, the CPA element, and the second connector housing. This segmentation allows each component to perform its specific function - the locking features provide primary connection while the CPA element provides secondary stabilization, resolving the contradiction between simple locking and vibration resistance
2Manufacturing precision
If manufacturing tolerances are reduced to eliminate free spaces, then connection precision improves, but manufacturing cost and complexity increase
Solution Approach 1:
Instead of changing the manufacturing precision parameters of the connector housings, the invention changes the physical state of the connection by introducing the CPA element. This element compensates for dimensional variations and tolerance accumulations, achieving precise connection without requiring stricter manufacturing controls
Solution Approach 2:
The CPA element serves as a mediator that absorbs the impact of manufacturing tolerances. By placing this intermediate component in the connection path, the system achieves accurate positioning and secure connection without needing to reduce the tolerances of the individual housing components, thus avoiding increased manufacturing complexity
3Strength
If locking features are designed for strong mechanical engagement, then connection strength improves, but the design becomes more complex with additional components
Solution Approach 1:
The CPA element combines multiple functions into a single component: it fills free spaces, prevents relative movement, and provides additional mechanical engagement. This merging approach achieves strong locking engagement without requiring multiple separate locking components, thus maintaining simplicity while improving strength
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 CPA element enhances the safety and reliability of the connector system by ensuring complete and secure connections, reducing wear and signal interruptions, and allowing for a simpler design with fewer parts and improved resistance to vibrations.
Implementation Method 1
a connector position assurance (CPA) element being configured to tension the first locking feature and the second locking feature relative to each other when the CPA element is assembled with the mated connector housings
Data Source
AI summary
The present disclosure refers to a connector system and particularly an electrical connector system. The connector system includes a first connector housing having a first locking feature. Further, the connector system includes a second connector housing being configured to mate with the first connector housing and having a second locking feature. The first and second locking feature are configured to directly or indirectly lock the first connector housing and the second connector housing with each other. Moreover, the connector system includes a connector position assurance (CPA) element being configured to tension the first locking feature and the second locking feature relative to each other when the CPA element is assembled with the mated connector housings.