Moveable Terminal Stabilizer for Connector Alignment Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connector designs with male plug terminals are prone to bending and misalignment due to non-axial forces, especially in high-density automotive connectors, and previous terminal stabilizers only provide protection during the initial mating process, failing to safeguard the terminals during subsequent connections and disconnections.
Innovation Solution
An electrical connector assembly featuring a moveable terminal stabilizer with a resilient spring member and integral lock retainer that maintains terminal alignment by shifting between stabilizing and stowed positions, protecting the terminals from bending and securing them within the connector body, and returns to the stabilizing position when disconnected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a male terminal stabilizer is included to protect terminal alignment, then terminal alignment is improved, but the stabilizer only provides protection during initial mating and fails to safeguard terminals during subsequent connections and disconnections
Solution Approach 1:
The terminal stabilizer is designed as a moveable component that transitions between a stabilizing position (extending toward the terminal tip) and a stowed position (retracted toward the base). This dynamic positioning allows the stabilizer to provide protection only when needed during connection/disconnection cycles, resolving the contradiction between providing continuous protection and allowing subsequent reconnections.
Solution Approach 2:
The stabilizer's position parameter is changed dynamically through the spring mechanism, allowing it to extend to the stabilizing position during disconnection events and retract to the stowed position during normal operation. This parameter change enables the stabilizer to adapt its protection level based on operational state, maintaining reliability while enabling multiple connection cycles.
2Reliability
If a moveable terminal stabilizer with spring member is used to provide continuous protection, then terminal alignment protection is improved throughout service life, but device complexity increases
Solution Approach 1:
The stabilizer mechanism is merged with the existing connector structure, where the stabilizer is integrated into the connector body and the spring member is housed within the same assembly. This merging reduces overall device complexity by consolidating multiple functions into a single integrated mechanism rather than adding separate components.
Solution Approach 2:
The spring member is designed to automatically return the stabilizer to the stabilizing position after it has been pushed to the stowed position during connection. This self-service mechanism eliminates the need for additional actuators or control systems, maintaining simplicity while achieving continuous protection throughout the service life.
3Reliability
If the terminal stabilizer is held in stabilizing position by spring force, then terminal protection is maintained, but insertion force requirement increases
Solution Approach 1:
The spring member is designed to provide sufficient force to return the stabilizer to the stabilizing position after connection, but not so much force as to create excessive insertion resistance. The spring is pre-loaded to a degree that ensures reliable return while keeping the insertion force within acceptable limits for the connector application.
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 effectively protects male plug terminals from bending throughout the service life of the connector, ensuring consistent alignment and simplifying assembly by integrating terminal stabilization and lock retention into a single part, reducing manufacturing complexity and costs.
Implementation Method 1
a resilient spring member mechanically coupled to the terminal stabilizer. The spring member is configured to exert an axial spring force on said terminal stabilizer, thereby holding the terminal stabilizer in the stabilizing position
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An electrical connector assembly (10) including a moveable terminal stabilizer (28) is presented. The terminal stabilizer (28) is moveable from a stabilizing position (44) to a stowed position (48). In the stabilizing position (44) the terminal stabilizer (28) is near the tips (46) of the terminals (24) and in the stowed position (48) is near the bases (50) of the terminals (24). The tips (46) of the terminals (24) are received in an aperture defined by the terminal stabilizer (28), whereby the terminal stabilizer (28) protects the terminal (24) from being bent away from the terminal axis (A) by a force applied to the terminal (24) in a direction substantially orthogonal to the terminal axis (A). The terminal stabilizer (28) also includes an integral lock retainer (64) that engages a terminal lock member (56) when the terminal stabilizer (28) is in the stowed position (48) thereby inhibiting movement of the lock member (56) and disengaging the lock member (56) when the terminal stabilizer (28) is in the stabilizing position (44) thereby allowing movement of the lock member (56).