Resilient Latch Electrical Connector Insert Retention
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Solution Overview
Problem
Conventional electrical connectors require additional retention devices like snap rings or clips to hold inserts in place, which complicate assembly, increase costs, and are prone to dislodging due to improper seating or insertion variations, especially in harsh environments.
Innovation Solution
The electrical connector design incorporates a shell with a chamber and an insert assembly featuring resilient latches that extend from the insert's outer periphery to engage the shell, eliminating the need for secondary retention devices by using a flange and groove mechanism to securely hold the insert assembly in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional retention devices like snap rings or clips are used to hold inserts in place, then the insert is retained in the shell, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The patent combines the retention function directly into the insert assembly by integrating resilient latches as part of the insert structure itself, eliminating the need for separate retention devices like snap rings or clips. This merging of functions reduces the number of components and simplifies the assembly process while maintaining reliable insert retention in the shell.
Solution Approach 2:
The resilient latches are designed to automatically engage with the shell during the insert loading process without requiring additional retention devices. The latches self-activate through the insertion motion itself, where the insert is loaded in a loading direction until the flange abuts the shoulder, causing the latches to deflect and engage with the shell, thereby retaining the insert assembly without external assistance.
2Reliability
If additional retention devices are added to hold inserts, then retention is improved, but manufacturing costs and part inventory increase
Solution Approach 1:
The retention function is merged into the insert assembly itself through integrally-molded resilient latches, eliminating the need for separate retention devices. This reduces the number of part numbers that need to be stocked and manufactured, thereby reducing manufacturing costs and inventory complexity while maintaining reliable retention.
Solution Approach 2:
The insert assembly is designed with multi-functionality by incorporating the resilient latches as an integral part of the insert structure. This single component serves both as the electrical contact carrier and as the retention mechanism, reducing the need for multiple specialized parts and simplifying manufacturing and inventory management.
3Reliability
If conventional retention mechanisms are used, then inserts can be retained, but they are prone to dislodging due to improper seating or insertion variations
Solution Approach 1:
The resilient latches provide dynamic retention through elastic deflection that automatically compensates for variations in insertion precision. As the insert is loaded into the shell, the latches deflect elastically to accommodate slight misalignments or seating variations, then engage securely with the shell. This dynamic response ensures reliable retention even when insertion precision varies within normal tolerances, preventing dislodging that would occur with rigid retention mechanisms.
Solution Approach 2:
The resilient latches utilize changes in physical state through elastic deformation to accommodate insertion variations. The material properties of the resilient latch allow it to temporarily change its dimensional parameters during insertion, absorbing seating variations, and then return to its original state to provide secure retention, thereby reducing sensitivity to manufacturing precision variations.
4Device complexity
If resilient latches are molded integral with the insert assembly, then assembly is simplified, but the latch structure must withstand harsh environments
Solution Approach 1:
The resilient latches are molded from materials with composite properties that provide both the necessary elasticity for simplified integral assembly and the durability to withstand harsh environments. The material composition is designed to resist extreme temperatures, corrosive contaminants, and physical forces while maintaining the resilient characteristics needed for automatic engagement and retention, thereby achieving both assembly simplicity and environmental durability.
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
This solution provides reliable retention of the insert assembly within the shell, preventing unintentional disengagement and reducing assembly complexities and costs, while ensuring the connectors can withstand harsh environments such as extreme temperatures, pressures, and corrosive contaminants.
Implementation Method 1
The resilient latches are biased towards being received in the groove
Data Source
AI summary
An electrical connector includes a shell with a chamber and an insert assembly received in the chamber. The insert assembly has cavities therethrough that are configured to receive contacts. The contacts are configured for electrical connection to mating contacts of a mating connector. The insert assembly has resilient latches extending from an outer periphery of the insert assembly that engage the shell to hold the insert assembly in the chamber.