Vehicle Lighting Connector Lock Cover With Flex Portion
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Solution Overview
Problem
Existing electrical connection devices for vehicular lighting systems are prone to loosening due to vibration and force inputs, often requiring complex and expensive configurations, and are susceptible to manufacturing defects and failures, leading to poor performance and reliability.
Innovation Solution
A vehicle lighting assembly featuring a fixed connector receptacle, a movable connector plug, and a lock cover with a roof flex portion that engages a rear positioning tab to secure the connection, ensuring a stable and lasting electrical connection through a simple and cost-effective assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complicated and expensive male/female connection configurations are used, then connection reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The connector is divided into a male connector portion and a female connector portion that separate and reconnect during deployment. This segmentation allows each portion to be simpler in structure while maintaining reliable connection when mated, resolving the contradiction between reliability and complexity
Solution Approach 2:
The male and female connector portions are pre-positioned on opposite sides of the housing before deployment. This preliminary positioning ensures that when the housing flexes and the connectors separate and reconnect, the connection is reliable without requiring complex locking mechanisms
2Reliability
If traditional spring biased connectors are used, then electrical connection is established, but connectors loosen over time due to vibration and force inputs
Solution Approach 1:
The connector design incorporates a flexible housing that allows dynamic separation and reconnection of the male and female portions during vehicle deployment. This dynamic behavior accommodates vibration and force inputs without causing the connector to loosen, extending service life while maintaining stability
3Reliability
If connectors are subjected to vehicle vibration and suspension forces, then electrical connection must be maintained, but connection failure occurs due to loosening
Solution Approach 1:
The flexible housing is designed to flex and separate the connector portions in response to vibration and force inputs from vehicle suspension. This controlled separation and reconnection converts the harmful effects of vibration into a benign cycling action that maintains connection reliability without causing failure
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 provides a secure, long-lasting electrical connection that withstands vehicle vibrations and forces, reducing the risk of accidental detachment and manufacturing defects, while simplifying the assembly process and reducing production costs.
Implementation Method 1
The roof can include two posts and a roof flex portion connecting the two posts. The roof flex portion can be configured to flex in an up-down direction.
Data Source
AI summary
A vehicle lighting assembly can include a fixed connector receptacle attached to a wiring board and configured for connection to a moveable connector plug and lock cover. The moveable connector plug has electrical wires extending from a rear end and can be inserted into the fixed connector receptacle. The lock cover can mate with both the fixed connector and the moveable connector plug to keep both structures in place after connection. The lock cover is configured to be rotatable around a front positioning portion of the lock cover when engaged in a positioning opening of the fixed connector receptacle. A rear positioning tab of the lock cover engages with a rear engagement aperture located on the moveable connector plug when in the fully assembled position to lock the moveable connector plug within the fixed connector receptacle.