Sliding Terminal Positioning for Partial Insertion Prevention
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Solution Overview
Problem
Electrical connector systems face assembly errors due to incorrect or insufficient terminal insertion, leading to increased manufacturing and assembly costs, complexity, and suboptimal terminal positioning, despite the use of terminal position assurance (TPA) devices.
Innovation Solution
A terminal positioning device with a sliding surface and terminal contact surfaces is integrated into the connector, allowing movement between open and closed positions to ensure proper terminal alignment and locking, utilizing a terminal holder with inclined locking protrusions and detents to maintain terminals in their optimal position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing TPA devices are implemented to detect partially seated terminals, then connector reliability is improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent combines the terminal positioning function and the TPA detection function into a single integrated device. The positioning device includes positioning features that guide terminal insertion and TPA features that detect partial seating, merging two previously separate functions into one unified component structure, thereby reducing overall device complexity while maintaining reliability
Solution Approach 2:
The positioning device is designed to perform multiple functions simultaneously: it provides mechanical positioning guidance for terminals, detects partial terminal seating through TPA features, and ensures proper terminal installation. This multi-functional design eliminates the need for separate TPA devices, reducing complexity and manufacturing costs while improving reliability
2Reliability
If existing TPA devices are implemented to ensure proper terminal insertion, then connector reliability is improved, but the space occupied within the connector increases
Solution Approach 1:
The patent integrates the TPA detection features within the positioning device structure itself, rather than using a separate TPA device. The positioning device includes both positioning features and TPA features in a single integrated component, significantly reducing the space required while maintaining the ability to detect partial terminal seating and ensure proper installation
Solution Approach 2:
The TPA features are nested within the positioning device structure, with detection elements integrated into the same housing and mechanism that provides positioning guidance. This nested arrangement allows the TPA functionality to be contained within the existing positioning device footprint, minimizing additional space requirements within the connector
3Reliability
If existing TPA devices are implemented to detect terminal positioning issues, then connector reliability is improved, but manufacturing and assembly costs increase
Solution Approach 1:
The patent combines terminal positioning and TPA detection into a single integrated device that can be manufactured as one unit. This merging of functions reduces the total number of parts, simplifies the manufacturing process, and lowers assembly costs compared to producing and assembling separate positioning and TPA devices, while maintaining the reliability benefits of TPA detection
Solution Approach 2:
The positioning device is designed as a universal component that performs both positioning guidance and TPA detection functions. This multi-functional design allows manufacturers to produce a single versatile part rather than multiple specialized components, reducing tooling costs, inventory requirements, and assembly operations, thereby lowering overall manufacturing and assembly costs while ensuring connector reliability
Data Source
AI summary
An electrical connector includes a terminal holder and a terminal positioning device. The terminal holder defines at least one terminal opening adapted to receive a terminal from a first side thereof in a terminal insertion direction. The terminal positioning device includes a sliding surface abutting a portion of the connector, and at least one terminal contact surface. The terminal positioning device is arranged adjacent the first side of the terminal holder. The device is movable relative to the terminal holder in an operating direction perpendicular to the insertion direction between a first position wherein the terminal positioning device does not overlap the at least one terminal opening in the insertion direction, and a second position wherein the at least one terminal contact surface overlaps the at least one terminal opening in the insertion direction.