Hinged Connector TPA Mechanism for Terminal Insertion Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing terminal position assurance (TPA) devices in electrical connectors suffer from excessive play between terminals and housings, particularly in small connectors, and do not adequately address assembly errors due to insufficient terminal insertion.
Innovation Solution
A hinged connector design with arcuate motion TPA elements that bias terminals toward hard stops, ensuring proper insertion and reducing play through a hinging or pivoting action, utilizing a first and second body with TPA devices and latches to secure terminals in optimal positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing TPA devices engage via linear sliding motion, then the connector assembly is simple, but excessive play between terminal and housing occurs and terminal insertion is not adequately ensured
Solution Approach 1:
The TPA element transitions from a static linear sliding mechanism to a dynamic arcuate motion mechanism that pivots about a fulcrum. This dynamic motion allows the TPA element to actively engage and bias the terminal along a curved path, ensuring complete insertion while reducing play between the terminal and housing.
Solution Approach 2:
The TPA element follows an arcuate path of motion rather than a linear path. The curved trajectory of the TPA element as it pivots about the fulcrum enables it to effectively engage the terminal and guide it into proper position, reducing excessive play while maintaining connector structure simplicity.
2Volume of moving object
If TPA devices are designed for small connectors, then connector size is reduced, but terminal play becomes more excessive and insertion errors increase
Solution Approach 1:
The arcuate motion mechanism provides a mechanical advantage that amplifies the TPA element's engagement force on the terminal. As the TPA element pivots along its arcuate path, it actively biases the terminal toward complete insertion, ensuring reliable terminal positioning even in compact connector designs where traditional linear mechanisms would allow excessive play.
3Ease of manufacture
If linear sliding TPA devices are used, then manufacturing is easier, but terminal play reduction and insertion assurance are insufficient
Solution Approach 1:
The arcuate path of motion is achieved through the geometric relationship between the TPA element and the fulcrum, rather than requiring complex curved guides or rails. This approach maintains manufacturing simplicity while achieving precise terminal insertion through the natural geometry of the pivoting mechanism.
Data Source
AI summary
A connector or connector assembly includes a first body hingedly connected to a second body and movable between a first and second position with respect thereto. The first body includes a first terminal position assurance (TPA) device, a first terminal space receiving a first terminal, and a first terminal latch engaging with the first terminal and securing it within the first terminal space. The second body includes a second TPA device, a second terminal space receiving a second terminal, and a second terminal latch engaging with the second terminal and securing it within the second terminal space. A TPA latch secures the first body and the second body in each of the first and second positions. In the second position, the first TPA device engages with the second terminal, and the second TPA device engages with the first terminal.