Adjustable-Tolerance Connector With Movable Guide for Reliable Coupling
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Solution Overview
Problem
Typical connectors face challenges in coupling due to cumulative tolerance issues between the header and groove, leading to manufacturing complexities and increased costs, especially when trying to maintain a small size and reduce positional defects.
Innovation Solution
A tolerance-adjustable connector with a housing made of a first synthetic resin and movable guides made of a second synthetic resin, allowing for slidable contact and movement, which can change tolerance when pushed by an opposing connector, thereby facilitating easy insertion and coupling, and a manufacturing method involving double injection molding to reduce costs and improve productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a typical connector with fixed tolerance is used, then manufacturing precision is maintained, but coupling reliability deteriorates due to cumulative tolerance issues between header and groove
Solution Approach 1:
The connector incorporates a movable guide that can dynamically adjust its position within a movable guide groove. This allows the connector to adapt to tolerance variations in the opposing connector during insertion, transforming a static tolerance issue into a dynamic adjustment problem that can be resolved in real-time during coupling.
Solution Approach 2:
The invention changes the positional parameter of the guide relative to the housing by allowing movement along the groove. This parameter change enables the connector to compensate for tolerance variations in the opposing connector, maintaining coupling reliability without requiring strict dimensional control throughout the entire assembly.
2Reliability
If floating connector is applied to resolve tolerance issues, then coupling reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The connector is segmented into distinct functional components: a housing, a movable guide, and a movable guide groove. This segmentation allows each component to perform its specific function - the groove provides the adjustment path, the guide moves within it, and the housing provides structural support - simplifying the overall design compared to a fully floating connector while maintaining coupling reliability.
Solution Approach 2:
The movable guide acts as an intermediary element between the housing and the opposing connector. It mediates the tolerance issues by absorbing positional variations through its movement within the groove, preventing these variations from affecting the coupling reliability between the header and groove.
3Manufacturing precision
If strict dimensional inspection is performed, then manufacturing precision is maintained, but productivity decreases and manufacturing cost increases
Solution Approach 1:
The connector design makes the system self-compensating for tolerance variations. The movable guide automatically adjusts to accommodate dimensional variations in the opposing connector during insertion, eliminating the need for external inspection and adjustment processes. This self-service mechanism maintains coupling reliability without requiring strict dimensional inspection.
Data Source
AI summary
Disclosed are a tolerance-adjustable connector and a method for manufacturing the same. The tolerance-adjustable connector comprises: a housing made of a first synthetic resin; and a movable guide that is made of a second synthetic resin that is not bonded to the first synthetic resin, is in slidable contact with the housing, and is movable relative to the housing.