Frustoconical Socket Terminal Retention in EVSE Connectors
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Solution Overview
Problem
Electrical socket terminals in connector assemblies, such as those used in EVSE charging couplers, often dislocate during assembly, necessitating a secure retention mechanism to ensure proper positioning and prevent environmental contamination.
Innovation Solution
The electrical connector assembly features a frustoconical socket terminal with axially slots and a circumferential flange that fits into a U-shaped slot in a dielectric terminal cartridge, with a locking protrusion to securely retain the terminal, and a crimping mechanism for wire attachment, all formed from conductive materials for reliable electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If socket terminals are machined from solid bar with circumferential flanges, then electrical and mechanical performance is improved, but terminal dislocation during assembly occurs
Solution Approach 1:
The invention divides the terminal retention system into two separate components: the socket terminal with its circumferential flange and the connector housing with a dedicated retention feature. This segmentation allows the terminal to maintain its electrical and mechanical performance while the housing feature independently provides positioning stability and prevents dislocation during assembly.
Solution Approach 2:
The circumferential flange on the socket terminal acts as an intermediary element that bridges the terminal body and the connector housing. This intermediate feature enables the terminal to be securely retained within the housing, preventing dislocation while maintaining the terminal's original electrical and mechanical properties.
2Stability of the object's composition
If socket terminals are secured with retention features, then terminal dislocation is prevented, but assembly complexity increases
Solution Approach 1:
Instead of modifying the entire connector assembly structure, the invention applies a localized retention feature within the connector housing that specifically addresses terminal positioning. This local quality approach prevents dislocation without increasing overall assembly complexity, as the retention mechanism is integrated into the housing design rather than requiring separate assembly steps.
3Stability of the object's composition
If manual securing methods are used for socket terminals, then terminal positioning is maintained, but labor time increases
Solution Approach 1:
The connector housing design incorporates an integrated retention feature that automatically secures the socket terminal during the assembly process. The terminal's circumferential flange engages with the housing feature in a self-securing manner, eliminating the need for manual securing operations and reducing assembly labor time while maintaining terminal positioning stability.
Data Source
AI summary
An electrical connector assembly is presented. The electrical connector assembly includes an electrical socket terminal having a frustoconical body that defines a first cylindrical cavity configured to receive a corresponding electrical plug terminal. The frustoconical body defines a plurality of axially slots extending to the first cylindrical cavity. The terminal further includes a cylindrical member extending from the frustoconical body. The cylindrical member defines a circumferential flange extending from an outer surface of the cylindrical member. The electrical connector assembly also includes a terminal cartridge formed of a dielectric material and defining a generally U-shaped slot having an open end, a closed end, two side walls, and a floor. The U-shaped slot is configured to receive the circumferential flange of the socket terminal. The floor defines a locking protrusion configured to contact the flange and retain the socket terminal within the U-shaped slot.