Male Terminal Stabilizer Locking for High-Force Connector Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional male terminal stabilizers in electrical connectors have low blocking forces, making them prone to premature release during shipping and handling, and require complex features that increase manufacturing costs.
Innovation Solution
An electrical connector assembly with a flexible pre-stage locking arm, angled rib features, and a male terminal stabilizer that moves from a pre-staged to a full staged position, using a hook feature to engage and disengage with retention and retraction faces to provide a higher blocking force and secure the stabilizer in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pre-stage locks with low blocking force (30-40 newtons) are used, then the mating female connector can easily push the male terminal stabilizer from pre-staged to full staged position, but the stabilizer may be prematurely released during shipping and handling
Solution Approach 1:
The pre-stage locking arm is designed as a flexible, movable component that transitions between engaged and disengaged states. During shipping, it maintains the stabilizer in pre-staged position with high blocking force. During mating, the locking arm bends to disengage, allowing the stabilizer to move to full staged position. This dynamic behavior resolves the contradiction by providing high blocking force when needed while enabling movement when required.
Solution Approach 2:
The locking mechanism changes the blocking force parameter from high (during shipping) to low or zero (during mating) through physical transformation. The flexible locking arm's deflection changes the engagement state, effectively changing the force parameter to match different operational requirements without compromising either shipping reliability or mating capability.
2Reliability
If complex features and geometric shapes are added to provide greater blocking force, then premature release during shipping is prevented, but tooling costs for manufacturing increase
Solution Approach 1:
The pre-stage locking arm is implemented as a flexible element within the connector body rather than a complex rigid geometric feature. This flexible arm provides the necessary blocking force through its elastic deformation capability, avoiding the need for complex tooling while achieving reliable stabilizer positioning during shipping and handling.
Solution Approach 2:
The flexible locking arm uses simple, inexpensive material and geometry that can be easily manufactured and replaced if needed. Rather than investing in complex tooling for durable geometric features, the design uses a simpler, more cost-effective flexible element that achieves the same functional goal with lower manufacturing costs.
3Reliability
If the male terminal stabilizer is held firmly in pre-staged position, then protection from premature release is improved, but the mating female connector cannot easily push it to full staged position
Solution Approach 1:
The locking mechanism is designed to be dynamic rather than static, allowing it to adapt its blocking force based on the operational phase. During shipping, the locked state provides firm holding. During mating, the flexible locking arm naturally deflects under the pushing force of the female connector, automatically transitioning from a firm hold to an engaged state that facilitates smooth operation.
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 provides a blocking force exceeding 100 newtons, preventing premature release and reducing manufacturing costs by simplifying the design while maintaining secure terminal alignment and positioning.
Implementation Method 1
a flexible pre-stage locking arm defining a pre-stage stop face
Implementation Method 2
the second connector body is configured to contact the pair of angled rib features and disengage the pre-stage stop face from the pre-stage stop tab when the first connector body is mated with the second connector body
Implementation Method 3
a flexible retraction arm having a hook feature on its distal end that engages a retraction face defined by the second electrical connector body when the first connector body is unmated from the second connector body, thereby pulling the male terminal stabilizer from the full staged position to the pre-staged position
Data Source
AI summary
An electrical connector assembly includes a first connector body, a male terminal stabilizer disposed within the first connector body that is movable from a pre-staged position to a full staged position, a second connector body, means for retaining the male terminal stabilizer in the pre-staged position until the second connector body is inserted within the first connector body, means for releasing the male terminal stabilizer from the pre-stage position and allow the second connector body to push the male terminal stabilizer to the full staged position, means for returning the male terminal stabilizer from the full staged position to the pre-staged when the second connector body is withdrawn from the first connector body, and means for retaining the male terminal stabilizer in the first connector body as the second connector body is withdrawn from the first connector body.