Integral Spring Tabs for Connector Contact Module Retention

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Solution Overview

Problem

Existing connector assemblies require multiple hardware pieces and assembly steps, increasing manufacturing costs and the risk of component damage during assembly.

Innovation Solution

A connector design featuring a housing with integral spring tabs and a ridge portion that securely holds a contact module, reducing the need for separate retention clips and simplifying the assembly process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate retention clips are used to hold the contact module within the housing, then the contact module can be secured in position, but the manufacturing cost increases and the assembly process becomes more complex

Engineering Contradiction:

Improvecontact module retentionVSAvoidnumber of hardware pieces

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The spring tabs are integrally formed with the housing, combining the retention function into the housing structure itself rather than using separate retention clips. This eliminates the need for additional hardware pieces while maintaining the contact module retention capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The spring tabs provide self-retaining functionality through their elastic deformation capability. When the contact module is inserted, the spring tabs automatically flex and engage with the contact module features, providing retention without requiring separate fastening operations or additional components.

Inventive Principle:

Principle #25Self-service

2Reliability

If separate retention clips are used to hold the contact module, then the contact module can be secured, but the manufacturing time and assembly time increase

Engineering Contradiction:

Improvecontact module retentionVSAvoidassembly speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The retention function is merged into the housing structure through integrally formed spring tabs, eliminating separate retention components and their associated assembly steps, thereby increasing assembly speed.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The spring tabs automatically engage with the contact module during insertion through their elastic deformation, providing self-retaining functionality that eliminates manual fastening operations and reduces assembly time.

Inventive Principle:

Principle #25Self-service

3Reliability

If separate retention clips are used to hold the contact module, then the contact module can be secured in position, but the risk of damaging components during assembly increases

Engineering Contradiction:

Improvecontact module retentionVSAvoidcomponent damage risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The spring tabs provide automatic retention through elastic deformation during contact module insertion, eliminating the need for separate fastening operations that could cause misalignment or damage to the contact module and housing components.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The spring tabs utilize elastic deformation as a parameter change to provide retention force, allowing for compliant engagement that accommodates manufacturing tolerances and reduces the risk of component damage during assembly.

Inventive Principle:

Principle #35Parameter changes

4Reliability

If multiple hardware pieces are used to assemble the connector, then the contact module can be retained, but the manufacturing cost increases

Engineering Contradiction:

Improvecontact module retentionVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The retention function is combined with the housing structure through integrally formed spring tabs, eliminating the need for separate retention clips and reducing the total component count, which lowers manufacturing cost.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The housing structure serves multiple functions: it provides mechanical support, defines the cavity, and includes integrally formed spring tabs for retention. This multi-functionality reduces the need for separate components and associated manufacturing costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 design minimizes the number of hardware pieces and assembly steps, lowering manufacturing costs and reducing the risk of component damage, while effectively retaining the contact module within the housing.

Implementation Method 1

a pair of spring tabs that are located in the cavity and oriented to project from the interior surface toward the first end of the housing

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentEP2347476B1Connectors including spring tabs for holding a contact module

Publication Date: 2017.04.12 TE CONNECTIVITY CORP

AI summary

A connector (100) configured to hold a contact module (120). The connector includes a housing (102) that has an interior surface (133) defining a cavity (104) that extends between first and second ends of the housing. The cavity is configured to receive and hold the contact module therein. The connector also includes a spring tab (122) that is located in the cavity and oriented to project from the interior surface toward the first end of the housing. The spring tab is integrally formed with the housing. Also, the connector includes a ridge portion (221-224) that is located in the cavity and oriented to project from the interior surface. The contact module is retained between the ridge portion and the spring tab.