Bent-Tube Connector Housing for Thick Cable Routing in Tight Spaces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power bolt-type connectors in new energy vehicles have a 180-degree straight line output direction, leading to space wastage and increased complexity in wiring, particularly for thicker cables, which results in reduced product consistency and higher costs due to the need for manual bending and multiple parts.
Innovation Solution
A connector with a housing in the form of a bent tube, allowing cables to be bent at angles other than 180 degrees, featuring a conductive core, insulating layers, shielding, and seals to provide electrical isolation, shielding, and waterproofing, with a reduced number of parts for simpler assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a 180-degree straight line output direction is used, then the connector structure is simple, but the occupied space increases and cable routing complexity increases
Solution Approach 1:
The patent applies curvature by designing the housing in a bent tube form with a bent portion that allows the cable to bend at predetermined angles (e.g., 90 degrees). This curved structure eliminates the need for manual cable bending while reducing the space required for cable routing compared to a straight 180-degree configuration.
2Adaptability or versatility
If manual cable bending is performed, then the connector can adapt to different routing needs, but product consistency decreases and rejection rate increases
Solution Approach 1:
The patent implements preliminary action by pre-forming the housing into a bent tube configuration with a predetermined bent portion during manufacturing. This pre-configured structure guides the cable along a fixed path, eliminating the need for manual bending operations and ensuring consistent product quality while maintaining routing flexibility.
3Reliability
If multiple parts are used for shielding, insulation, and waterproofing, then the connector provides comprehensive protection, but the number of parts increases and assembly complexity increases
Solution Approach 1:
The patent applies merging by integrating multiple protective functions into a unified bent tube housing structure. The housing combines shielding, insulation, and waterproofing capabilities in a single integrated component, reducing the total number of parts and simplifying assembly while maintaining comprehensive protection functions.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A connector including a housing (1) in a form of a bent tube is disclosed. The housing includes a first tubular portion (101), a second tubular portion (102) and a bent portion (103) connected between the first tubular portion and the second tubular portion, so that the first tubular portion and the second tubular portion extend at an angle of more than 0 degree and less than 180 degrees relative to each other. The housing (1) is adapted to hold a cable (12) extending through the interior of the housing, so that the cable is bent within the bent portion (103). A connector assembly is also disclosed.