Angled Plug Connector Assembly with Integrated Sealing
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Solution Overview
Problem
Conventional methods for assembling angle connectors are laborious, error-prone, and costly, with issues related to watertightness and the need for multi-part housings, which complicate the assembly process and increase manufacturing costs.
Innovation Solution
A method involving a one-piece connector housing with a right-angled through-channel, where a first conductor component is held non-positively in a prefabrication position and inserted further into the channel to connect with a second conductor component, eliminating the need for additional sealing and housing parts, and utilizing a press connection for conductor components to ensure watertightness and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealing material or adhesive is used to make the connector housing watertight, then watertightness is improved, but assembly labor and error probability increase
Solution Approach 1:
The patent merges the sealing function into the housing structure itself by providing an integrated sealing element that is formed as part of the housing during molding. This eliminates the need for separate sealing materials or adhesives, thereby maintaining watertightness while significantly reducing assembly labor and eliminating the errors associated with manual sealing operations.
Solution Approach 2:
The housing is designed to be self-sealing through an integrated sealing element that automatically provides watertight protection when the housing is assembled. The sealing element is configured to engage with the cable and housing structure without requiring additional sealing materials or manual intervention, making the system self-sufficient for achieving watertightness.
2Reliability
If sealing material or adhesive is used to make the connector housing watertight, then watertightness is improved, but manufacturing costs increase
Solution Approach 1:
The sealing function is merged into the housing structure through an integrated sealing element that is molded as part of the housing. This eliminates the need for separate sealing materials and the associated costs of manufacturing, transporting, and assembling multiple components, thereby reducing overall manufacturing costs while maintaining watertightness.
Solution Approach 2:
The patent uses a cost-effective integrated sealing element that is molded into the housing during the primary manufacturing process. This approach eliminates the need for expensive separate sealing materials and reduces the overall cost of achieving watertight protection, making the solution economically efficient.
3Reliability
If a multi-part housing is used to achieve watertightness, then sealing is improved, but device complexity increases
Solution Approach 1:
The patent combines the housing and sealing elements into a single integrated structure. The sealing element is molded as an integral part of the housing, eliminating the need for separate housing parts and their associated assembly steps. This simplifies the overall device structure while maintaining effective watertight protection.
4Ease of manufacture
If conductor components are connected inside the through-channel, then assembly simplicity is improved, but connection precision requirements increase
Solution Approach 1:
The patent employs preliminary positioning features such as positioning elements and guiding structures that are pre-formed in the housing and conductor components. These features guide the conductor components into the correct positions during assembly, ensuring precise connections are achieved automatically as the components are inserted and assembled, thereby maintaining connection precision while simplifying the assembly process.
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a method for assembling an angled plug connector (100) with a plug connector housing (10), which has a through channel (12) preferably angled at a right angle in order to receive conductor components (14, 16) extending at an angle relative to one another, wherein a first conductor component (14) introduced from one side (X) into the through channel (12) in the interior of the through channel is connected by non-positive and/or by positive engagement to a second conductor component (16) introduced from the other side (Y) into the through channel (12). The invention further relates to an assembly unit (200) for carrying out said method.