Retainer Clip Augments Retention Force for Automotive Wire Harness Connectors
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Solution Overview
Problem
Conventional electrical connectors, such as mini-bridge connectors, provide insufficient retention force to prevent unintentional separation of wire harness connectors from printed circuit board headers in applications like automotive LED headlamps.
Innovation Solution
An injection molded thermoplastic retainer clip is used to augment the retention force by providing a positive mechanical engagement between the wire harness connector and the printed circuit board header, utilizing a deformable retaining arm and support base to enhance the connection stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a conventional locking latch on mini-bridge connectors is used, then the connector can be easily assembled and disassembled, but the retention force is insufficient (approximately 20N) to prevent unintentional separation in automotive LED headlamp applications
Solution Approach 1:
A retainer clip is introduced as an intermediary component between the connector and the PCB header. This separate retention mechanism works in conjunction with the existing locking latch, providing additional retention force without modifying the original connector design. The retainer clip engages with both the connector housing and the PCB header, creating a mechanical interlock that supplements the insufficient 20N retention force of the conventional latch.
Solution Approach 2:
The retention function is segmented into two independent mechanisms: the original locking latch for basic connection and disconnection operations, and the additional retainer clip for enhanced retention force. This segmentation allows each component to perform its specific function optimally - the latch provides ease of operation while the retainer clip provides the necessary 20N+ retention force to prevent unintentional separation.
2Reliability
If the retention force is increased to prevent unintentional separation, then the connection reliability is improved, but the ease of operation for assembling and disassembling the connector may be reduced
Solution Approach 1:
The retainer clip incorporates a flexible or deformable element that allows dynamic engagement and disengagement. During assembly, the retainer clip can be temporarily deformed to allow insertion, then automatically snaps into its retained position providing high reliability. During intentional disassembly, applying sufficient force to deform the flexible element releases the retention, allowing easy removal. This dynamic behavior maintains both high retention force and ease of operation.
Data Source
AI summary
Retainer clip (100) attachable to motor vehicle headlamp (10) for inhibiting second electrical connector (72) of wiring harness (44) from unintentionally separating from mating first connector (52) on the PCB (60) of the lamp. Retainer clip comprises a deformable retaining arm (110) configured to inhibit separation of the first connector (52) and a second connector (72) upon assembly thereof with the first connector (52) and the second connector (72); a second connector receptacle (140) defined by retainer clip body (102), the second connector receptacle (140) configured to receive the second connector (72) therein; and a support base (160) configured to cooperate with the motor vehicle lamp (10) to align the second connector (72) with the first connector (52) in a connection plane (82) to assemble the second connector (72) and the first connector (52).