Floating Alignment Member for Electrical Connector Terminal Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing receptacle connectors lack protection for terminals when the plug connector is unmated, making them susceptible to damage from foreign objects and stubbing during handling and mating.
Innovation Solution
A dielectric housing with a movable alignment member that transitions between seated and supporting positions, providing protection to terminals by controlling the exposure of terminal pins and preventing damage through a latch mechanism that adjusts the alignment member's position based on the mating state of the plug connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the plug connector is unmated and removed from the mating cavity, then the terminals are exposed within the mating cavity, but the terminals become susceptible to damage from foreign objects and stubbing
Solution Approach 1:
The alignment member is positioned in advance to support the terminals before unplugging occurs. When the plug connector is unmated, the alignment member automatically moves to a supporting position that extends into the terminal cavities, preventing terminal exposure and potential damage from foreign objects or stubbing during handling.
Solution Approach 2:
The alignment member serves as an intermediary protective element between the terminals and the external environment. It physically blocks foreign objects from contacting exposed terminals and prevents stubbing damage by maintaining terminal support even when the plug connector is removed from the mating cavity.
2Object-affected harmful factors
If the alignment plate is positioned to support terminals when unmated, then terminal protection is improved, but terminal alignment during mating may be compromised
Solution Approach 1:
The alignment member is designed to be movable between two positions: a supporting position that extends into terminal cavities to protect terminals when unmated, and a seated position that retracts to allow proper terminal alignment during mating. This dynamic adjustment resolves the contradiction by adapting the alignment member's position to the operational state of the connector.
Solution Approach 2:
The position parameter of the alignment member is changed based on the mating state. When the plug connector is mated, the alignment member is pushed to its seated position (retracted), allowing precise terminal alignment. When unmated, it moves to the supporting position (extended), providing terminal protection. This parameter change enables the system to achieve both protection and alignment precision.
3Manufacturing precision
If a fixed alignment plate is used, then terminal alignment is maintained, but terminal protection when unmated is lost
Solution Approach 1:
The alignment member transitions from a fixed alignment plate design to a dynamic, movable structure that can adjust its position. It moves between a seated position for alignment during mating and a supporting position for protection when unmated, thereby achieving both terminal alignment precision and terminal protection that a fixed structure cannot provide.
Data Source
AI summary
An electrical connector includes a dielectric housing having a mating cavity extending to a base wall and at least one terminal cavity through the base wall to the mating cavity. The terminal cavity being configured to receive a terminal therein having a pin extending into the mating cavity. A primary terminal lock extends from an interior wall of the housing and is configured to engage the terminal to retain the terminal in the terminal cavity. An alignment member is received within the mating cavity and has an alignment plate having at least one opening aligned with a corresponding terminal cavity. The alignment member is movable within the mating cavity between a seated position in which the alignment plate is proximate to the base wall and a supporting position in which the alignment plate is positioned remote from the base wall. A tip of the terminal is held within the opening when the alignment member is in the supporting position, and a pin base of the terminal is held within the opening when the alignment member is in the seated position.