Back-Retainer Connector Structure for Wire Swing Isolation
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Solution Overview
Problem
In electric vehicles and hybrid vehicles, the high voltage and large current wires tend to swing, causing external forces that can lead to increased contact resistance, plating wear, and sparks due to contact separation when the wire swing is transmitted to the connector terminal.
Innovation Solution
A connector design featuring a housing with a back retainer that includes a wire insertion hole and a wire holding piece projecting from the peripheral edge. The wire is tied and fixed to the wire holding piece using a tying tool, effectively absorbing and dispersing external forces caused by wire displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the wire is simply pulled out from the housing without additional fixing structures, then the device complexity is reduced, but the wire swing transmits external forces to the terminal causing contact resistance increase and plating wear
Solution Approach 1:
The wire holding piece is pre-formed as an integral part of the back retainer structure, projecting from the peripheral edge of the wire insertion hole. This preliminary preparation allows the wire to be easily tied and fixed without requiring additional components or complex assembly steps, thus maintaining simplicity while ensuring reliable wire fixation and preventing terminal contact instability
Solution Approach 2:
The wire holding piece acts as an intermediary element between the wire and the back retainer. It provides a dedicated structure for the tying tool to engage with the wire, distributing the fixing force and preventing wire swing from transmitting external forces to the terminal, thereby protecting the terminal contact stability without complicating the overall connector structure
2Reliability
If the wire is tied and fixed to the wire holding piece using a tying tool, then the transmission of external forces to the terminal is suppressed, but the ease of manufacture is reduced due to additional assembly steps
Solution Approach 1:
The wire holding piece is designed as a self-contained structure that protrudes from the back retainer, providing its own fixation function. The tying tool simply needs to wrap around the wire and secure it to this pre-formed holding piece, eliminating the need for additional fixtures, tools, or complex assembly procedures. This self-service design maintains ease of manufacture while ensuring reliable wire fixation stability
Solution Approach 2:
The back retainer is segmented to include a distinct wire holding piece that projects from its peripheral edge. This segmentation creates a dedicated fixation zone that separates the wire tying function from the rest of the back retainer structure, allowing for simple and straightforward assembly while ensuring reliable wire fixation and preventing external force transmission to the terminal
Data Source
AI summary
It is aimed to provide a connector of a novel structure capable of suppressing or preventing the transmission of the swing of a wire to a terminal in a connector. A connector 10 is provided with a housing 16 for accommodating a terminal 12, a back retainer 20 mounted in a rear end part of the housing 16 from which a wire 18 connected to the terminal 12 is pulled out, a wire insertion hole 62 provided in the back retainer 20, and a wire holding piece 72 projecting in a pull-out direction of the wire 18 from a peripheral edge part of the wire insertion hole 62. The wire 18 pulled out from the wire insertion hole 62 is tied and fixed to the wire holding piece 72 by a tying tool 82.