Integrated Coaxial Connector with Front-Loaded Locking
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Solution Overview
Problem
Existing connector assemblies separate coaxial and terminal connections, requiring separate components and lacking a compact packaging solution that ensures secure locking of both coaxial and terminal connections.
Innovation Solution
A connector assembly with a male housing featuring coaxial and terminal cavities, and a corresponding female housing with lance and wedge structures that interact to lock coaxial and terminal connections, providing a compact and secure connection system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If coaxial and terminal connections are separated into different components, then each connection type can be independently designed and manufactured, but the overall packaging space requirement increases and the connector assembly becomes more complex
Solution Approach 1:
The patent combines coaxial and terminal connections into a single integrated connector assembly. The male connector includes both a coaxial cavity for receiving coaxial terminals and terminal cavities for receiving terminal connections, allowing both connection types to be housed in one compact unit rather than requiring separate components.
Solution Approach 2:
The connector assembly is designed to perform multiple functions simultaneously - it can establish both coaxial connections and terminal connections through a single housing unit. The male and female housings each contain both coaxial and terminal cavities, enabling the same connector structure to handle different types of electrical connections.
2Volume of moving object
If coaxial and terminal connections are integrated into a single connector assembly, then packaging space is reduced, but the device complexity increases due to the need for multiple cavities and locking structures
Solution Approach 1:
The connector assembly is segmented into distinct functional zones within a unified housing. The male connector contains separate coaxial and terminal cavities, each with its own positioning and locking features. This segmentation allows complex functionality to be organized into manageable, modular sections that can be independently designed and assembled.
Solution Approach 2:
The connector design employs nested structures where terminal cavities are positioned within or adjacent to the coaxial cavity structure. The female housing is shaped to be disposed within the male housing, creating a nested arrangement that maximizes space utilization while maintaining distinct functional areas for different connection types.
3Reliability
If separate locking mechanisms are used for coaxial and terminal connections, then each connection can be independently secured, but the device complexity and number of components increases
Solution Approach 1:
The locking mechanisms for coaxial and terminal connections are merged into a single integrated locking system. The front loaded terminal position assurance structures in both male and female housings simultaneously lock both coaxial and terminal connections when the housings are mated, eliminating the need for separate locking mechanisms.
Solution Approach 2:
The connector design incorporates self-aligning and self-locking features. The cam structures formed on the coaxial cavity automatically align and hold the coaxial terminal in position during insertion. The front loaded terminal position assurance structures with lances and wedges automatically lock the connections as the housings are mated, reducing the need for additional manual locking operations.
4Manufacturing precision
If cam structures are added to the coaxial cavity for terminal alignment, then terminal positioning accuracy is improved, but the manufacturing complexity of the housing increases
Solution Approach 1:
The cam structures are designed with specific geometric parameters that enable automatic alignment during the insertion process. By optimizing the cam profile angles and dimensions, the structure provides precise terminal positioning through simple geometric interaction rather than requiring complex adjustment mechanisms or post-manufacturing calibration.
Data Source
AI summary
A connector assembly includes a male housing having at least one coaxial cavity and terminal cavities. At least one female housing is shaped to be disposed in the male housing when in a connected position. The at least one female housing includes a corresponding coaxial cavity relative to the male housing and corresponding terminal cavities relative to the male housing. At least one front loaded male terminal position assurance structure is disposed in the male housing. At least one front loaded female terminal position assurance structure is connected to the at least one female housing. The front loaded male and female terminal position assurance structures lock coaxial connections and terminal connections within the male and female housings when in the connected position.