Flexible Beam Terminal Retention in Electrical Connectors
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Solution Overview
Problem
Existing electrical connector systems with flexible locking tangs or fingers are complex, bulky, and prone to disengagement, making them difficult to manufacture and tool, and they often require two separate pieces, leading to unreliable terminal retention within the connector body.
Innovation Solution
An electrical connector system featuring a terminal receiving cavity defined by a rigid floor with a rigid lock nib, a first flexible beam extending rearward, and a second flexible beam extending forward, both engaging the terminal to bias it towards the rigid floor and prevent disengagement, along with an angled channel for tool access and removal, formed using additive manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flexible locking tangs or fingers are formed as part of the terminal or connector body, then terminal retention is provided, but the structure becomes complicated and bulky with at least two separate pieces
Solution Approach 1:
The patent combines multiple functions into a single integrated terminal structure. The terminal includes both the electrical contact portion and the flexible locking tang as one piece, eliminating the need for separate assembly operations and reducing structural complexity while maintaining reliable retention
2Reliability
If flexible locking tangs or fingers are used, then terminal retention is provided, but the connector body becomes large and bulky and difficult to tool and injection mold
Solution Approach 1:
The flexible locking tang is integrated directly into the terminal body as a single molded piece. This consolidation allows the entire terminal assembly to be injection molded in one operation, eliminating complex multi-step tooling processes and reducing manufacturing difficulty while maintaining the retention function
3Ease of manufacture
If conventional injection molding is used, then manufacturing is simplified, but complex shapes required for additive manufacturing cannot be achieved
Solution Approach 1:
The patent utilizes the design freedom provided by additive manufacturing to create complex internal geometries and integrated features that would be impossible with conventional injection molding. The additive process allows for intricate locking tang configurations and internal reinforcement structures while maintaining manufacturing efficiency
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 provides reliable terminal retention with lower insertion force, allows for verification and removal without damaging mating surfaces, and enables complex shapes that are difficult to achieve with conventional injection molding, enhancing the stability and accessibility of the connector system.
Implementation Method 1
a first flexible beam extending into a rearward portion of the terminal receiving cavity overlying the rigid floor, and a second flexible beam distinct from the first flexible beam also extending into a forward portion of the terminal receiving cavity and overlying the rigid floor
Data Source
AI summary
An electrical connector system including a connector having a terminal cavity within. The cavity has a rigid floor with a lock nib extending into the cavity, a first flexible beam extending into a rearward portion of the cavity and a second flexible beam extending into a forward portion. The first and second beams both overlie the floor. The system further includes a terminal having a top surface and a bottom surface defining a rigid lock edge. The terminal is received in the cavity such that the first beam engages a rearward portion of the top surface of the terminal and the second beam engages a forward portion of the top surface, thereby biasing the terminal towards the floor. The lock edge engages the lock nib, thereby preventing the terminal from being inadvertently withdrawn from the terminal receiving cavity. The connector may be formed by an additive manufacturing process.