Angled Connector With Segmented Guide Sleeves
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Solution Overview
Problem
Existing angled connectors are difficult to assemble due to the need for bending and securing cables at precise angles, which complicates the manufacturing process and increases the risk of errors.
Innovation Solution
The angled connector design features two guide sleeves coupled at an angle with straight cable passages, allowing the cable to be routed without kinks, and secured through a clamp connection, facilitating easy assembly and secure fixation during encapsulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the cable is bent through 90° and cast in this bent position to create an angled connector, then the angled connector can be formed, but the cable has to be fixed in the angled position both during casting and during the subsequent drying of the casting compound, which complicates the assembly process
Solution Approach 1:
The guide assembly is divided into two separate guide sleeves (first guide sleeve and second guide sleeve) that are coupled together at an angle. Each guide sleeve has a straight cable passage, allowing the cable to pass through without bending. The segmentation eliminates the need to bend and fix the cable at an angle during assembly, as each sleeve can be assembled independently and then coupled together to form the angled configuration.
Solution Approach 2:
The clamp connection acts as an intermediary mechanism that couples the two guide sleeves together at a defined angle. This clamp connection secures the relative angular position of the two guide sleeves without requiring the cable itself to be bent or fixed at an angle, thereby simplifying the assembly process while maintaining the angled connector configuration.
2Manufacturing precision
If an angled guide sleeve is used to fix the cable in an angled position during casting, then the cable positioning is achieved, but it is cumbersome and expensive when manufacturing the connector
Solution Approach 1:
Instead of using a single complex angled guide sleeve, the invention segments the guide into two separate guide sleeves with straight passages. Each guide sleeve can be manufactured independently using standard manufacturing processes, avoiding the need for complex angled guide sleeve fabrication. The two sleeves are then coupled together at the required angle, achieving precise cable positioning without the manufacturing complexity and cost of a single angled component.
Solution Approach 2:
The cable is threaded through both guide sleeves in their straight, uncoupled state before the guide sleeves are coupled together at the angle. This preliminary action of threading the cable through straight passages simplifies the manufacturing process, as it eliminates the need to bend or position the cable at an angle during assembly. The coupling of the guide sleeves afterward secures the cable in the desired angled configuration without requiring complex positioning operations.
3Shape
If the cable is routed through bent passages in a single guide sleeve, then the angled connector is formed, but the assembly process becomes more difficult and time-consuming
Solution Approach 1:
The guide assembly is segmented into two separate guide sleeves, each with a straight cable passage. This segmentation allows the cable to be threaded through both sleeves quickly and easily in a straight line, without requiring bending or complex positioning operations. The two guide sleeves are then coupled together at the required angle to form the angled connector configuration, significantly reducing assembly time and increasing productivity while maintaining the desired angled shape.
Solution Approach 2:
The cable is preliminarily threaded through the cable passages of both guide sleeves while they are in a convenient, uncoupled state. This preliminary threading action through straight passages is much faster and easier than attempting to bend and route the cable through angled passages. Afterward, the guide sleeves are coupled together at the angle, finalizing the angled connector configuration without requiring time-consuming cable manipulation operations.
Data Source
Figure 1~2
Figure 3~5A
Figure 4B~5B
AI summary
An angled connector (100) has a plug end (101) for insertion and a cable end (102) from which a cable extends out of the connector (100). The cable is guided from the plug end (101) to the cable end (102) in cable channels (KG1, KG2) of two guide sleeves (130, 140), the two guide sleeves (130, 140) being coupled to each other such that the cable channels (KG1, KG2) are arranged at an angle (103) to each other. The two cable channels (KG1, KG2) of the first and second guide sleeves (130, 140) are essentially straight.