Offset Pin Connector Layout for Secure High-Voltage Coupling
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Solution Overview
Problem
Existing electrical connectors lack effective mechanisms for ensuring secure and reliable coupling and terminal positioning, particularly in high-voltage applications, leading to potential disconnection and misalignment issues.
Innovation Solution
A male housing design with offset and angled pins, combined with a terminal position assurance (TPA) and connector position assurance (CPA) mechanism, provides secure coupling and ensures proper terminal alignment through visual, tactile, and auditory feedback, enhancing resistance to decoupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical connectors are used without offset and angled pins, then the structure is simpler, but the coupling stability and terminal positioning accuracy are insufficient
Solution Approach 1:
The patent applies asymmetry by offsetting the second row of pins relative to the first row and angling the pins at different orientations. This asymmetric pin arrangement prevents misalignment and ensures precise terminal positioning while maintaining coupling stability, resolving the contradiction between reliability and structural simplicity.
Solution Approach 2:
The patent introduces dimensional variation by arranging pins at different angles and offsets rather than in a single straight line. This multi-dimensional pin configuration enhances coupling stability and terminal positioning accuracy, addressing the reliability improvement while accepting increased structural complexity.
2Strength
If pins are arranged in a straight line, then the manufacturing is easier, but the resistance to decoupling force is reduced
Solution Approach 1:
The asymmetric pin arrangement with offsets and angles distributes decoupling forces across multiple directions, increasing overall resistance to decoupling. While this requires higher alignment precision during manufacturing, the enhanced strength and stability justify the manufacturing complexity.
3Manufacturing precision
If the connector housing is made larger to accommodate offset pins, then the terminal positioning accuracy is improved, but the profile height increases
Solution Approach 1:
The patent optimizes the geometric parameters of the pin offsets and angles to achieve precise terminal positioning within a compact housing. By carefully selecting the offset distances and angles, the design maintains high positioning accuracy while minimizing the connector profile height, resolving the contradiction between precision and compactness.
Data Source
AI summary
An electrical connector is provided. The electrical connector can be a low profile, high voltage connector that can include a male housing and a female housing. The male housing can support male pins that mate with terminals disposed through the female housing. The bend or outward extension of the pins can support forming one row or dual rows of solder pads.