Terminal Position Assurance Locking for Compact Electrical Connectors

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Solution Overview

Problem

Existing electrical connectors lack effective mechanisms to ensure proper terminal positioning and prevent unintended withdrawal, particularly in complex vehicle wiring systems where space is limited and reliability is critical.

Innovation Solution

The electrical connector incorporates an asymmetrical terminal position assurance member with fixed and cantilevered lock arms that engage retention apertures in the female housing, providing a pre-lock and final lock position, and offering visual, tactile, and audible feedback to confirm secure installation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a terminal position assurance member is used to ensure proper terminal positioning, then terminal positioning reliability is improved, but the connector size increases due to additional external components

Engineering Contradiction:

Improveterminal positioning reliabilityVSAvoidconnector size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The terminal position assurance member is nested within the internal cavity of the connector housing, with lock arms that engage with retention apertures formed in the housing walls. This integration eliminates the need for external assurance components while maintaining terminal positioning reliability through the interaction between the lock arms and retention structures.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The terminal position assurance function is merged with the connector housing structure itself. The retention apertures and lock arm mechanisms are integrated into the housing design, combining the housing and terminal assurance functions into a single unified structure rather than separate components.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If a locking mechanism is added to prevent unintended withdrawal, then connection reliability is improved, but device complexity increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidconnector complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The locking mechanism is segmented into discrete functional elements: lock arms (with fixed and cantilevered variants), retention apertures, and intermediate steps. Each segment performs a specific locking function, allowing the complex overall mechanism to be constructed from simpler, modular components that are easier to manufacture and assemble.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The lock arms incorporate dynamic elements including spring-loaded cantilevered arms that automatically engage and disengage, and movable intermediate steps that provide staged locking positions. This dynamic behavior enables automatic locking upon insertion and controlled release, reducing the need for additional control mechanisms.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS12548935B2Connector with terminal position assurance

Publication Date: 2026.02.10 JST CORP

AI summary

An electrical connector is provided. The electrical connector can include a female housing and a terminal position assurance member forming a pre-installed assembly. The terminal position assurance member can include one or more lock arms to retain the terminal position assurance member in a final lock position, which can provide reinforcement or secondary locking for a terminal, and terminal position assurance.