Automotive Electrical Terminal Locking Lance Design
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Solution Overview
Problem
Designing robust yet elastic metal locking lances for miniaturized electrical terminals in automotive connectors is challenging due to their small dimensions, requiring improved retention and dynamic load performance while maintaining reduced mating force and increased lifetime.
Innovation Solution
The locking lance is designed astride an intermediate bar extending along the insertion direction, distributing pull-out force across the terminal body and incorporating a coding ridge for orientation prevention, with a flexible configuration that includes a slot and an intermediate bar to manage stress and deformation, enhancing retention force to at least 30N.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the terminal dimensions are reduced to achieve miniaturization, then the packaging size and cable dimensioning are reduced, but the robustness and retention force of the locking lance become challenging to maintain
Solution Approach 1:
The locking lance is divided into two functional segments: a first portion that is elastically linked to the terminal body and a second portion that extends beyond the terminal body to engage the housing. This segmentation allows each portion to be optimized independently - the first portion for elastic deformation and the second portion for engagement - thereby maintaining locking strength despite overall miniaturization.
Solution Approach 2:
The locking lance is designed to extend in a direction that is not collinear with the terminal body's longitudinal axis, creating a angular relationship between the two components. This dimensional change allows the locking lance to leverage housing features for retention while minimizing the space required within the terminal body itself.
2Force
If the locking lance is made more robust to improve retention force, then the retention force increases, but the mating force and insertion difficulty increase
Solution Approach 1:
The locking lance is designed with elastic properties in its first portion, allowing it to dynamically deform during insertion and then spring back to engage the housing. This dynamic behavior enables the locking lance to provide high retention force in the locked state while requiring minimal force during the insertion process, as the elastic portion absorbs the insertion energy.
3Force
If the locking lance extends beyond the terminal body to engage the housing, then the retention force is improved, but the terminal body becomes more complex
Solution Approach 1:
The locking lance is integrated with the terminal body through elastic linkage rather than being a separate component. This merging of the locking function into the terminal body structure itself eliminates the need for additional separate locking mechanisms, thereby improving retention force without proportionally increasing overall device 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
This design effectively distributes retention force and improves the retention of miniaturized terminals in their cavities, ensuring robustness and flexibility, while maintaining sealing integrity and reducing the risk of cracking during stress.
Implementation Method 1
The locking lance is elastically linked to the terminal body so as to retract along this terminal body during the insertion of the terminal in its housing cavity and to spring back for engaging a stop in the housing when in place in this cavity.
Data Source
AI summary
Electrical terminal (30) for automotive vehicle connectors comprising cage (34) extending in a terminal insertion direction (D) between a front opening (35) and tail (31). A locking lance (36) extends longitudinally substantially in the insertion direction (D) above the top wall from a joint (39) to a free end (38). The locking lance (36) is astride an intermediate bar (60) which extends substantially along the insertion direction (D) from a front portion (61) to a rear portion (62) respectively linked to the front end and the rear end of the cage (34).