Integrated TPA Connector Assembly Without Hinge Failure
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Solution Overview
Problem
Existing electrical connectors face challenges in manufacturing terminal position assurance devices (TPAs) that are cost-effective and reliable, with separate components adding complexity and hinges prone to damage in high-temperature applications.
Innovation Solution
The electrical connector integrates a TPA device with the housing through a single injection molding process, using sacrificial connecting tabs that break during assembly to ensure proper terminal positioning, eliminating the need for separate components and hinges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate terminal position assurance device is manufactured and assembled into the housing, then proper terminal positioning can be achieved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The terminal position assurance device is merged with the housing into a single integrated component manufactured through co-injection molding. The first material forms the housing, and the second material forms the TPA device within the housing body, eliminating separate manufacturing and assembly steps while maintaining positioning functionality
Solution Approach 2:
The housing is designed to serve multiple functions: it provides structural enclosure, terminal support, and integrated terminal position assurance through the co-molded TPA device. This multi-functionality reduces the number of separate components needed in the connector assembly
2Ease of operation
If a hinge is used to connect the terminal position assurance device to the housing, then the device can move between positions, but the hinge becomes susceptible to damage and breakage over time
Solution Approach 1:
The patent uses breakaway tabs made of a brittle material that is sacrificial by design. These tabs are intended to break during normal operation to release the TPA device from its initial position, allowing movement without requiring a durable hinge mechanism. The tabs are replaced after use, ensuring reliability through replacement rather than durability
Solution Approach 2:
The patent changes the material parameter of the connecting tabs to use a brittle material with different mechanical properties than the housing. This parameter change allows the tabs to break at specific points under controlled conditions, enabling device movement without the need for complex hinge mechanisms
3Reliability
If ductile plastic material is used to reduce hinge breakage risk, then hinge durability improves, but suitability for high temperature applications decreases
Solution Approach 1:
The patent employs composite material construction with the housing made from one material and the TPA device made from a different material with suitable temperature characteristics. This allows each component to be optimized for its specific functional requirements, including temperature resistance
Solution Approach 2:
The patent changes the material parameter of the TPA device and connecting tabs to use materials specifically selected for high-temperature stability. This allows the device to maintain its positioning function and structural integrity in high-temperature environments where ductile plastics would fail
Data Source
AI summary
An electrical connector includes a housing having a terminal cavity between a front and a rear. The housing has an access window open to the terminal cavity and device walls forming a device channel aligned with the access window. The electrical connector includes a terminal in the terminal cavity having a mating end and a terminating end. The electrical connector includes a TPA device received in the device channel configured to move between an open position and a closed position. The TPA device includes an interference element configured to interface with a positioning element of the terminal in the closed position to assure proper positioning of the terminal in the terminal channel. The TPA device includes sacrificial connecting tabs holding the TPA device at the open position configured to be separated to release the TPA device and allow movement of the TPA device from the open position to the closed position.