Retractable Terminal Stabilizer for Low-Force Electrical Connectors
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Solution Overview
Problem
Current retractable terminal stabilizer systems in electrical distribution centers require high coupling force for mating and unmating, leading to fatigue and failure over time, where the stabilizer may remain undesirably positioned, increasing the risk of terminal damage and repair costs.
Innovation Solution
An electrical connector assembly with a retractable terminal stabilizer featuring retraction fins, retraction locks, release ramps, and beam locks that reduce coupling force and allow the stabilizer to move from a seated to a pre-staged position using a resilient member, ensuring easy retraction and protection of terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a retractable terminal stabilizer plate is used to protect terminals and prevent debris intrusion, then terminal protection and connection reliability are improved, but high coupling force is required during mating and unmating operations
Solution Approach 1:
The stabilizer plate transitions from a static component to a dynamic one, automatically moving between a retracted position (during mating) and an extended position (during normal operation). This dynamic behavior allows the system to provide terminal protection when needed while minimizing interference during connection operations, thereby reducing the required coupling force.
Solution Approach 2:
The stabilizer plate is pre-positioned in a retracted state before mating occurs, eliminating the need for high coupling force to overcome its resistance. After mating is complete, the plate automatically extends to provide terminal protection. This preliminary positioning resolves the contradiction by ensuring the stabilizer is out of the way during the critical mating phase.
2Reliability
If the stabilizer plate remains in a seated position during disconnection, then terminal protection is maintained, but the stabilizer may become fatigued and fail to retract properly over time
Solution Approach 1:
The stabilizer plate incorporates a spring mechanism that automatically returns the plate to its retracted position after each mating cycle without requiring external intervention. This self-service capability ensures consistent operation over the service life of the connector, preventing fatigue-related failures while maintaining terminal protection during normal use.
Solution Approach 2:
The stabilizer plate undergoes periodic motion between retracted and extended positions with each mating and unmating cycle. This regular, controlled movement prevents the plate from remaining in a stressed seated position indefinitely, thereby reducing fatigue accumulation and extending the service life of the component.
3Force
If the stabilizer plate is made movable to enable retraction, then coupling force is reduced, but the device complexity increases due to additional moving parts
Solution Approach 1:
The stabilizer plate is integrated with the connector housing structure, combining the protective function with the existing mechanical framework. The spring mechanism is embedded within the housing, merging multiple functions (protection, retraction, positioning) into a unified structure rather than adding separate components, thereby minimizing the increase in device complexity.
Solution Approach 2:
The stabilizer plate serves multiple functions: protecting terminals from damage, preventing debris intrusion, and automatically retracting to facilitate mating. By consolidating these functions into a single component rather than using separate mechanisms for each function, the design achieves multi-functionality without proportionally increasing complexity.
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
The solution reduces the overall coupling force needed to mate and unmate the connection system, prevents terminal damage by ensuring proper retraction of the stabilizer, and decreases repair costs by maintaining the stabilizer in a ready position during disconnection.
Implementation Method 1
a resilient member projecting from a bottom surface of the terminal stabilizer configured to exert a spring force on the base in order to urge the terminal stabilizer from the seated position to the pre-staged position
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
An electrical connector assembly (10) includes a connector (12), a corresponding mating-connector (20), and a terminal-stabilizer (38). The a connector (12) has a plurality of electrical-terminals (14). The connector (12) also has an outer-surface (16) that includes a plurality of retraction-fins (18). The mating-connector (20) has a plurality of mating-electrical-terminals (22). The mating-connector (20) is releasably connected to the connector (12) along a mating-axis (24). The mating-connector (20) includes a connector- shroud (30) having side walls (32) defining a shroud-cavity (34). The terminal- stabilizer (38) is slideably disposed within the shroud-cavity (34) and includes a plurality of retraction-locks (40) that engage the plurality of retraction-fins (18) on the connector (12). The terminal- stabilizer (38) defines a plurality of terminal-apertures (42) that slideably engage the plurality of mating-electrical-terminals (22). The terminal- stabilizer (38) is moveable from a prestaged-position (44), when the connector (12) and the mating-connector (20) are in the unmated-position (26), to a seated-position (46), when the connector (12) is moved to the mated-position (28). The connector (12) retracts the terminal-stabilizer (38) from the seated-position (46) to the prestaged-position (44) when the connector (12) is moved from the mated-position (28) to the unmated-position (26).