Double TPA Connector Locking for Mixed Terminal Pitches

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Solution Overview

Problem

Traditional electrical connectors lack adequate mechanisms to ensure precise terminal positioning and accommodate terminals with different pitches, leading to potential misconnections, disconnections, signal loss, and electrical failures under mechanical and environmental stress.

Innovation Solution

A double TPA mechanism with movable first and second TPA members, each associated with regions of different pitches, allowing for flexible terminal spacing and secure locking through interconnected movement and engagement mechanisms like drivers and followers, hooks, and telescopic connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional single TPA mechanism is used, then the structure is simple, but it cannot accommodate terminals with different pitches

Engineering Contradiction:

Improveaccommodation of different terminal pitchesVSAvoidTPA mechanism structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The TPA mechanism is divided into multiple independent TPA members (first TPA member, second TPA member), each capable of accommodating terminals with different pitches. This segmentation allows each TPA member to be optimized for specific pitch requirements while maintaining overall system functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each TPA member is designed with universal features including connecting means that can interface with both the housing and adjacent TPA members, allowing the same structural design to serve multiple functions across different pitch configurations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple independent TPA members are used for different pitches, then adaptability to different terminal pitches is improved, but the assembly process becomes more complex

Engineering Contradiction:

Improveterminal pitch flexibilityVSAvoidassembly process

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The connecting means of adjacent TPA members are merged into a single integrated structure that performs multiple functions: it connects the housing to the first TPA member, connects the first TPA member to the second TPA member, and provides guiding features for both. This merging simplifies the assembly process by reducing the number of separate components and connection steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connecting means acts as an intermediary element between adjacent TPA members, facilitating their coordinated movement and alignment during assembly. The guiding features within the connecting means serve as mediators that ensure proper positioning without requiring complex alignment procedures.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If TPA members are rigidly fixed, then positioning precision is high, but the locking mechanism lacks flexibility for different terminal configurations

Engineering Contradiction:

Improveterminal positioning precisionVSAvoidflexibility for different terminal pitches

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The TPA members are designed with movable characteristics, allowing them to transition between different positions and orientations to accommodate terminals with different pitches. The connecting means provides guided movement that maintains precision while enabling adaptability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system allows for changes in geometric parameters (position, orientation, spacing) of the TPA members to adapt to different terminal pitch requirements, while maintaining precise positioning through the guiding features provided by the connecting means.

Inventive Principle:

Principle #35Parameter changes

4Reliability

If complex connecting means are used to link TPA members, then coordinated movement is achieved, but the device complexity increases

Engineering Contradiction:

Improvecoordinated locking reliabilityVSAvoidconnecting means structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The connecting means is designed to automatically guide and coordinate the movement of adjacent TPA members during assembly and operation, without requiring external intervention or complex control mechanisms. The integrated guiding features enable the system to self-align and self-coordinate.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The connecting means serves as a mediator that simplifies the interaction between TPA members by providing a unified interface that handles both mechanical connection and movement coordination, reducing the overall system complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP4697518A1Double TPA for different cavity pitches

Publication Date: 2026.02.18 APTIV TECHNOLOGIES AG

Figure 1~2
Figure 3~4A
Figure 4B~5A

AI summary

An electrical connector assembly (1), comprises a connector housing (2) adapted to receive a plurality of terminals; a first (100) and a second (200) terminal position assurance (TPA) member, wherein the first and the second TPA members are adapted to be mounted to the connector housing (2) and being movable relative to the connector housing between a pre-lock position and a final-lock position; a terminal header (3) arranged in the connector housing comprising a first region (31) having a first pitch (110) between the terminals and a second region (32) having a second pitch (210), wherein the first pitch is larger than the second pitch, where the first TPA (100) is associated with the first region and the second TPA (200) is associated with the second region.