Rigid Terminal Position Assurance for Repeatable Connector Locking
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Solution Overview
Problem
Conventional connector assemblies with cantilever beam designs for terminal position assurance (TPA) suffer from degradation and insufficient error-proof force, leading to potential function failure and fracture due to repeated use.
Innovation Solution
A rigid TPA design with a main body, upper and lower boards, and extension arms that switch between pre-installed and fully-installed states, using engaging portions and stoppers to secure the terminal position without detaching from the connector, ensuring stable electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cantilever beam design is adopted for TPA, then the TPA can provide locking function for male terminal, but the cantilever beam structure degrades under repeated use leading to function failure
Solution Approach 1:
The patent inverts the conventional cantilever beam design by using a rigid TPA structure that moves linearly within a dedicated slot rather than flexing. The TPA is guided by positioning grooves and engaged by positioning protrusions, transforming the flexible deformation mechanism into a rigid guided motion mechanism, thereby eliminating cantilever beam degradation while maintaining locking functionality.
Solution Approach 2:
The patent introduces positioning grooves in the connector housing and positioning protrusions on the TPA as intermediary elements. These intermediaries guide the TPA's movement and engagement, providing precise positioning and stable engagement without relying on cantilever beam flexing. The positioning mechanisms act as mediators between the TPA and connector housing, ensuring reliable locking while preventing degradation.
2Ease of operation
If a floating TPA structure is used, then the TPA can be easily installed, but the error-proof force is insufficient and fracture risk increases
Solution Approach 1:
The TPA structure is segmented into distinct functional components: a main body for engagement, an extension arm for positioning, and a stopper for error-proofing. This segmentation allows each component to perform its specific function optimally while being supported by the rigid main body, preventing fracture and providing sufficient error-proof force while maintaining ease of installation.
Solution Approach 2:
The TPA employs a composite structure combining a rigid main body with extended arms and stoppers. The rigid main body provides structural strength and fracture resistance, while the extended portions provide functional capabilities for positioning and error-proofing. This composite design maintains overall strength while enabling easy installation and sufficient error-proof force.
3Stability of the object's composition
If a rigid TPA structure is adopted, then material yielding is avoided under repeated use, but the TPA requires precise positioning mechanisms
Solution Approach 1:
The patent merges the positioning function into the basic TPA structure itself through integrated positioning grooves and protrusions. Rather than adding separate complex positioning mechanisms, the positioning features are combined with the TPA body and connector housing, achieving precise positioning with minimal additional complexity while maintaining rigid structural stability.
Data Source
Figure 1
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Figure 3A~3B
AI summary
A terminal position assurance and corresponding connector assembly are disclosed. The terminal position assurance may comprise a main body including a main board, an upper board and a lower board, wherein the upper board and the lower board are perpendicular to the main board and are located on the same side of the main board, and the upper board and the lower board have distal ends away from the main board, an extension arm extending from the distal end of the upper board in a direction substantially perpendicular to the main board, and a stopper extending from an outer edge of the extension arm and thus going beyond the main body.