Integrated Electrical Connector TPA and Secondary Lock
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Solution Overview
Problem
Existing electrical connector systems with secondary locks face challenges such as increased production and packaging costs due to separate molding and assembly of housing and terminal position assurance (TPA) elements, along with risks of lost or misplaced parts during installation.
Innovation Solution
An electrical connector with a dielectric housing featuring a primary terminal lock and an integrally formed secondary locking member with a flexible hinge, which provides terminal retention and position assurance without the need for separate molds or pre-assembly, allowing for reduced manufacturing and packaging costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate TPA elements and secondary locks are used, then terminal retention and position assurance are improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent combines the housing, secondary lock, and TPA element into a single integrated component molded as one piece. This eliminates the need for separate parts and their associated assembly steps, while maintaining all the retention and positioning functions that separate components would provide
Solution Approach 2:
The integrated component performs multiple functions simultaneously: it provides the housing structure, secondary locking mechanism, and terminal position assurance features all in one element, reducing the overall part count and simplifying the assembly process
2Manufacturing precision
If separate TPA elements are used, then terminal position assurance is improved, but production cost increases
Solution Approach 1:
The housing and TPA element are merged into a single molded part, eliminating the need for separate molding operations and assembly steps. This integration reduces production costs while maintaining the precise terminal position assurance features built into the integrated structure
3Reliability
If pre-assembly of housing and TPA elements is performed, then terminal retention is improved, but packaging cost and complexity increase
Solution Approach 1:
By combining the housing and TPA element into one integrated component, the patent eliminates the need for pre-assembly operations and special packaging requirements. The single integrated part can be handled and packaged more simply while maintaining all retention functions
4Reliability
If multiple separate parts are used, then terminal retention and position assurance are improved, but risk of lost or misplaced parts increases
Solution Approach 1:
The patent merges multiple separate parts (housing, secondary lock, TPA element) into a single integrated component. This eliminates the risk of losing or misplacing separate small parts during installation, while maintaining all the retention and positioning functions through the integrated design
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 enables a low-cost, reliable connector system with reduced manufacturing and packaging expenses while ensuring secure terminal retention and easy visual indication of proper seating, eliminating the need for special packaging and separate components.
Implementation Method 1
The secondary locking member has a flexible hinge member proximate the contact loading end that pivotably connects the secondary locking member to the housing
Implementation Method 2
The secondary locking member includes an engagement end that is received in the housing in a direction transverse to the axis of the at least one contact cavity to provide a visible indication of a seating condition of the terminal contact
Implementation Method 3
The secondary locking member includes a latch element that engages a ledge in the housing to lock the secondary locking member in a closed position
Implementation Method 4
A primary terminal lock extends from an interior wall of the housing and is configured to engage a terminal contact to retain the terminal contact in the at least one contact cavity
Data Source
AI summary
An electrical connector includes a dielectric housing having at least one contact cavity extending along a longitudinal axis between a mating end and an opposite contact loading end. A primary terminal lock extends from an interior wall of the housing and is configured to engage a terminal contact to retain the terminal contact in the at least one contact cavity. A secondary locking member is integrally formed with the housing. The secondary locking member has a flexible hinge member proximate the contact loading end that pivotably connects the secondary locking member to the housing. The secondary locking member includes an engagement end that is received in the housing in a direction transverse to the axis of the at least one contact cavity to provide a visible indication of a seating condition of the terminal contact.