Electrical Connector Housing With Spring Lock Terminal Repair
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connectors require multi-piece plastic insulative housings or multiple sealing interfaces, and are often unrepairable if terminals are damaged.
Innovation Solution
A one-piece integrally formed connector housing with a cylindrical spring lock retainer and annular ridges, featuring a cold-formed spring lock retainer stops, secures terminals and allows for removal and repair using a removal tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-piece plastic insulative housings are used to securely hold terminals, then terminal retention is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple housing pieces into a single integrated housing structure that contains all terminal retention features (cavities, ridges, and spring lock retainers) as built-in components. This consolidation maintains secure terminal retention while eliminating the complexity of assembling multiple separate housing pieces.
2Device complexity
If sealed electrical connectors with one-piece housing are used, then device complexity is reduced, but repairability deteriorates as terminals cannot be removed and replaced
Solution Approach 1:
The patent segments the terminal retention system into a removable spring lock retainer component that can be independently manipulated. The retainer includes spring members and locking features that allow terminals to be released and replaced through access openings in the one-piece housing, maintaining structural simplicity while enabling repairability.
3Reliability
If multiple sealing interfaces are used in sealed electrical connectors, then sealing reliability is improved, but device complexity increases
Solution Approach 1:
The patent integrates sealing features directly into the one-piece housing structure and terminal retainer design, eliminating the need for separate sealing components and multiple sealing interfaces. The housing and retainer are designed with built-in sealing capabilities that maintain reliability while reducing overall structural 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 provides secure terminal retention and repairability within a single-piece housing, enhancing durability and ease of maintenance.
Implementation Method 1
a cylindrical spring lock retainer disposed within a cavity in the housing and defining a spring member and a terminal lock
Implementation Method 2
The plurality of spring lock retainer stops are cold formed by deforming grooved portions of the inner walls
Data Source
AI summary
An electrical connector includes an integrally formed cylindrical housing and a cylindrical spring lock retainer disposed within a cavity in the housing and defining a spring member and a terminal lock. The electrical connector further includes an annular ridge protruding from inner walls of the housing into the cavity and a plurality of spring lock retainer stops extending from the inner walls into the cavity and arranged around a circumference of the spring lock retainer. The annular ridge is arranged on a first end of the spring lock retainer and the plurality of spring lock retainer stops are arranged on a second end of the spring lock retainer opposite the first end. A method of manufacturing such an electrical connector is also presented.