Terminal Alignment Plate with Flexible Beams for Connector Protection
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Solution Overview
Problem
Electrical connector assemblies face issues with terminal alignment and protection during shipping, as alignment plates can easily move, exposing terminals to contaminants and risking damage due to improper engagement with mating connectors, leading to potential damage or replacement.
Innovation Solution
An electrical connector assembly with a terminal alignment and protection plate featuring rigid support members and flexible support beams that maintain terminal alignment and protection during shipping, securely engaging with the mating surface upon connector mating, utilizing retention projections and alignment ribs to prevent movement and ensure proper alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an alignment plate is provided to maintain terminal alignment and prevent bending, then terminal protection and alignment are improved, but the alignment plate can easily move during shipping from a protecting position to a non-protecting position
Solution Approach 1:
The alignment plate is designed to be movable between a first position (where terminals are protected) and a second position (where terminals are not protected), allowing it to adapt to different operational states while maintaining reliability in the protected state during shipping
Solution Approach 2:
The alignment plate is positioned in the first position before mating occurs, preliminarily protecting the terminals from damage and misalignment during shipping and handling. The plate remains in this protective position until the connector is ready for mating
2Reliability
If the alignment plate remains in the first position during mating, then terminal protection is maintained, but the alignment plate interferes with proper engagement with the mating connector
Solution Approach 1:
The alignment plate transitions from a static protective element to a dynamic component that moves between positions. During mating, the plate moves from the first position to the second position, allowing engagement while maintaining protection during shipping
Solution Approach 2:
The alignment plate performs its protective function preliminarily during shipping and handling in the first position, then moves to the second position to allow mating, ensuring protection is maintained when needed but does not interfere with operation
3Ease of operation
If terminals are exposed to the ambient environment through the open front end, then ease of insertion is improved, but contaminants may enter the receiving cavity and electrical contacts may be damaged
Solution Approach 1:
The alignment plate serves as an intermediary element that protects terminals from contaminants while allowing proper engagement. It acts as a barrier between the exposed front end and the receiving cavity, filtering out harmful factors
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 effectively protects terminals from damage during shipping and ensures proper alignment with mating connectors, reducing the risk of stubbing and terminal damage, while maintaining secure engagement and alignment throughout the assembly process.
Implementation Method 1
The flexible support beams are provided in the terminal alignment member receiving channels and are retained between the first retention projections and the second retention projections
Implementation Method 2
Rigid support members extend from the first surface of the terminal alignment and protection plate in a direction away from the second surface. The support members extend perpendicular to a planar portion of the terminal alignment and protection plate
Data Source
AI summary
An electrical connector assembly having a housing and a terminal alignment and protection plate. A mating surface of the housing has terminal alignment member receiving channels. The terminal alignment member receiving channels have first retention projections and second retention projections which extend into the terminal alignment member receiving channels. Rigid support members extend from a first surface of the terminal alignment and protection plate in a direction away from a second surface. The support members extend perpendicular to a planar portion of the terminal alignment and protection plate. The support members have flexible support beams which extend between the support members. The flexible support beams extend essentially parallel to the planar portion of the terminal alignment and protection plate.