Removable Faceplate Connector for Easier Terminal Access
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Solution Overview
Problem
Traditional electrical connectors with integrated terminal access windows are often expensive and complex to manufacture, requiring delicate tooling prone to damage and time-consuming inspections.
Innovation Solution
An electrical connector design featuring a removable faceplate with a primary lock and rotatable terminal position assurance (TPA) features that secure terminals in the connector body, using simplified tooling and reducing the risk of manufacturing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional connectors use integrated terminal access windows in the connector body, then terminal access is enabled, but manufacturing complexity and cost increase
Solution Approach 1:
The connector is divided into separate components: a connector body and a removable faceplate. The faceplate contains the terminal access windows and can be detached independently from the connector body, allowing simplified manufacturing of each component while maintaining the terminal access function.
Solution Approach 2:
The terminal access windows are extracted from the connector body and placed on a separate removable faceplate. This extraction allows the faceplate to be manufactured separately with simpler tooling, reducing the complexity and cost of manufacturing the main connector body.
2Reliability
If traditional connectors use integrated terminal access windows, then terminal access is provided, but tooling damage risk increases
Solution Approach 1:
By segmenting the connector into a body and a separate faceplate, the delicate tooling required for creating terminal access windows is only needed for manufacturing the faceplate, not the entire connector assembly. This reduces the risk of tooling damage during manufacturing and maintenance.
Solution Approach 2:
The faceplate with terminal access windows can be manufactured as a separate, potentially replaceable component. If the faceplate becomes damaged or worn, it can be replaced without replacing the entire connector assembly, reducing the impact of tooling damage and manufacturing risks.
3Productivity
If traditional connectors use integrated terminal access windows, then terminal access is enabled, but inspection time increases
Solution Approach 1:
The removable faceplate allows inspectors to quickly access and inspect terminals by simply removing the faceplate from the connector body, without needing to disassemble the entire connector. This segmented design significantly reduces inspection time and improves productivity.
Solution Approach 2:
The terminal access windows are extracted onto a removable faceplate that can be quickly detached to provide direct access to terminals for inspection purposes, eliminating the time-consuming process of disassembling integrated connector designs.
4Ease of manufacture
If a removable faceplate is used, then manufacturing is simplified, but terminal security may be compromised
Solution Approach 1:
TPA features are pre-positioned on the faceplate and automatically engage with terminals when the faceplate is installed. This preliminary positioning ensures that terminals are secured during the assembly process without requiring additional complex locking mechanisms.
Solution Approach 2:
TPA features act as intermediary elements between the faceplate and terminals. These features provide a reliable mechanical connection that secures terminals to the connector body through the faceplate, maintaining terminal retention despite the removable faceplate design.
Data Source
AI summary
An electrical connector that includes a removeable faceplate is described. The removeable faceplate includes a primary lock and at least one terminal position assurance (TPA) feature coupled to the removeable faceplate by a hinge. The TPA feature is moveable via the hinge to be seated in an opening in a connector body to interact with terminal(s) carried in the connector body to secure the terminal(s) in the connector body.