Terminal Lock Connector Assembly with Position Assurance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connector assemblies for electric terminals lack sufficient resistance to prevent accidental removal of terminals from their housing, which is critical for maintaining proper operation of electric components in vehicles over their lifespan.
Innovation Solution
A connector assembly featuring a terminal lock with a lock arm and tab, combined with a terminal position assurance mechanism that moves between pre-lock and lock positions, limiting the terminal lock's movement to ensure the electric terminals remain securely installed, utilizing a resilient arm and retainer latches to prevent removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resilient arm terminal lock is used to retain electric terminals in the housing, then the terminal lock can engage the terminal body to prevent accidental removal, but the terminal lock may still be insufficient to prevent determined pulling forces from removing the terminal
Solution Approach 1:
The patent combines the terminal lock mechanism with a terminal position assurance component into an integrated assembly. The terminal position assurance includes a lock arm with a lock tab that engages with the terminal, and when properly installed, it moves to a lock position where it is retained by the housing. This merging of functions creates a more robust retention system that can withstand determined pulling forces while maintaining reliability for preventing accidental removal.
Solution Approach 2:
The lock tab of the terminal lock is designed with a curved surface that complements the curved engagement surface of the terminal. This curved geometry allows for smooth engagement and distributes the pulling forces more effectively across the contact surfaces, enhancing the resistance to removal while maintaining reliable retention.
2Ease of operation
If the terminal position assurance is designed to move between pre-lock and lock positions to indicate proper installation, then installation verification is improved, but the mechanism adds complexity to the connector assembly
Solution Approach 1:
The terminal position assurance is designed to automatically move between pre-lock and lock positions based on the installation state of the terminal. When the terminal is properly installed, the lock arm is pushed into the lock position by the terminal body itself, providing automatic verification without requiring additional manual operations or complex control mechanisms. This self-service approach maintains ease of operation while minimizing added complexity.
Solution Approach 2:
The terminal position assurance component serves multiple functions: it acts as both a retention mechanism (lock arm with lock tab) and an installation verification indicator (position movement between pre-lock and lock states). By combining these functions into a single component, the patent reduces overall assembly complexity compared to having separate retention and verification mechanisms.
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 prevents electric terminals from being pulled out of the housing, maintaining their installed position and ensuring reliable operation by resisting forces applied to remove them, thereby enhancing the durability and reliability of the connector assembly.
Implementation Method 1
A typical terminal lock includes a resilient arm that engages the body of the electric terminal when the electric terminal is installed in the housing
Implementation Method 2
A terminal lock is adapted to retain an electric terminal in the terminal cavity in an installed position. The terminal lock includes a lock arm that extends from the connector housing and a lock tab that extends from the lock arm into the terminal cavity
Implementation Method 3
The terminal position assurance is attached to the connector housing for relative movement between pre-lock position and a lock position
Data Source
AI summary
A connector assembly includes a connector housing that defines a terminal cavity that extends along a cavity axis. A terminal lock is adapted to retain an electric terminal in the terminal cavity in an installed position. The terminal lock includes a lock arm that extends from the connector housing and a lock tab that extends from the lock arm into the terminal cavity. The connector assembly also includes a terminal position assurance that is attached to the connector housing for relative movement between a pre-lock position and a lock position. When the terminal position assurance is in the lock position, it limits movement of the terminal lock away from the cavity axis and it limits movement of the terminal lock toward the cavity axis.