High-Voltage Connector Latch With Integrated Position Assurance
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Solution Overview
Problem
Existing electrical connectors lack effective connector position assurance mechanisms to ensure secure and reliable connection between components, particularly in high voltage applications.
Innovation Solution
The electrical connector features a latch mechanism with a lift bar accessible through a window, allowing for secure mating and locking, and a terminal position assurance mechanism with movable TPA latches to ensure proper terminal installation, along with a connector position assurance that locks into place using assurance arms and locks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a connector position assurance mechanism is added to ensure secure connection, then reliability is improved, but device complexity increases
Solution Approach 1:
The connector position assurance (CPA) mechanism is merged with the latch assembly, where the CPA block is integrated into the latch structure and the CPA feature is combined with the latch arm. This integration allows the connector to provide both latching function and position assurance function through a single unified structure, improving reliability while minimizing the increase in device complexity.
Solution Approach 2:
The latch assembly is designed to serve multiple functions: it provides the primary latching action to secure the connector, incorporates the CPA block for position verification, and includes the lift bar for tool engagement. By making the latch assembly multi-functional, the patent avoids adding separate independent mechanisms for each function, thus improving connection reliability without proportionally increasing device complexity.
2Reliability
If a latch mechanism with multiple components is used to prevent accidental disconnection, then reliability is improved, but ease of operation deteriorates
Solution Approach 1:
The lift bar serves as an intermediary element that mediates between the external tool and the latch arm. By providing this intermediate lever arm, the mechanism allows a simple tool insertion motion to be translated into the complex sequence of latch arm movements required to release the CPA block and disengage the latch, thereby improving ease of operation while maintaining the multi-component reliable latching structure.
Solution Approach 2:
The latch mechanism incorporates dynamic movement through the latch arm that can pivot between engaged and disengaged positions, and the CPA block that can move between locked and unlocked states. This dynamic design allows the complex multi-component system to be operated through a single continuous motion of the lift bar, making the operation easier despite the complexity of the internal mechanism.
3Reliability
If assurance arms and locks are added to the connector position assurance mechanism, then reliability is improved, but device complexity increases
Solution Approach 1:
The assurance arms and assurance locks are merged with the existing latch structure. The CPA block incorporates both the assurance arms that extend to engage with corresponding features on the mating connector, and the assurance locks that work with the lift bar mechanism. This merging ensures that position assurance functionality is achieved without requiring completely separate independent mechanisms, thus improving reliability while controlling the increase in device complexity.
Data Source
AI summary
An electrical connector includes a connector housing with a connector body. A connector cavity extends through the connector body and defines a connector axis. A shroud is connected to the connector body by a shroud wall. The shroud defines a window. A latch is attached to the connector housing for movement relative to the connector body between a latched position and a release position. The latch is located at least partially between the shroud and the connector body. The latch has a block that is adapted to engage a corresponding catch on a corresponding connector in order to retain the electrical connector in a mated position relative to the corresponding connector. The latch also includes a lift bar. The window is adapted to allow a tool to be inserted through the window to engage the lift bar.