Position Assurance Assembly for Electrical Connector Alignment

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing electrical connectors are not suitable for high-current or high-voltage applications and lack position assurance assemblies to ensure accurate alignment of male and female terminals during mating.

Innovation Solution

A position assurance assembly comprising an elongated fastener, a cover, a first position assurance part, a mounting surface, and a second position assurance part, which engage to secure the cover and mounting surface together, ensuring accurate alignment and secure engagement of electrical connectors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If prior art electrical connector designs are used, then manufacturing simplicity is maintained, but position assurance and alignment accuracy of male and female terminals are insufficient

Engineering Contradiction:

Improvealignment accuracy of male and female terminalsVSAvoidcomplexity of position assurance assembly

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The position assurance assembly is divided into separate components: a first position assurance part integrated into the housing, a second position assurance part integrated into the terminal, and a fastener. This segmentation allows each component to perform its specific alignment function independently, ensuring precise terminal alignment while maintaining manufacturing simplicity through modular design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The position assurance parts are pre-formed and integrated into the housing and terminal before assembly. The first position assurance part is formed as an integral part of the housing, and the second position assurance part is formed as an integral part of the terminal, ensuring alignment is established before the final fastening operation occurs.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If standard electrical connector designs are used, then ease of manufacture is maintained, but reliability for high-current or high-voltage applications is insufficient

Engineering Contradiction:

Improvereliability for high-current or high-voltage applicationsVSAvoidease of manufacture of position assurance assembly

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The position assurance function is merged with the existing housing and terminal structures. The first position assurance part is formed as an integral part of the housing, and the second position assurance part is formed as an integral part of the terminal, combining alignment functionality with structural components to maintain ease of manufacture while improving reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The position assurance assembly serves multiple functions: it provides alignment guidance for male and female terminals, ensures proper positioning during assembly, and maintains reliable electrical connection for high-current or high-voltage applications. The fastener both secures the terminal to the housing and ensures proper alignment through the position assurance parts.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If position assurance parts are added to ensure accurate alignment, then alignment precision is improved, but device complexity increases

Engineering Contradiction:

Improvealignment precision of terminalsVSAvoidnumber of components in assembly

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS8056867B2Position assurance assembly for an electrical connector

Publication Date: 2011.11.15 JST CORP

AI summary

A position assurance assembly includes an elongated fastener, a cover forming a cavity, a first position assurance part, a mounting surface, a second position assurance part and a fastener receptacle. The cover has a hole formed therethrough and is in communication with the cavity. The hole is sized to receive the fastener. The first position assurance part is connected to the cover and disposed inside of the cavity. The second position assurance part and the fastener receptacle are connected to and project from the mounting surface. Upon covering the second position assurance part and the fastener receptacle with the cover, the first position assurance part and the second position assurance part matably engage one another and, with the hole and the fastener receptacle in at least substantial registration with one another, the fastener extends through the hole and into the fastener receptacle for releasable engagement therewith.