Segmented Cable Connector Housing for Vibration-Stable Impedance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrical connectors in automotive applications face reliability issues due to vibration and shock, which cause impedance fluctuations and affect connector performance by loosening connections between terminals, wires, and cable sleeves.
Innovation Solution
A cable connector design featuring an inner housing with first and second housings that securely hold a cable assembly, including terminals, wires, and a sleeve, through specific holding portions to prevent shaking and maintain impedance stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cable connector structure is used, then the device complexity is low, but the reliability deteriorates due to shaking and loosening under vibration and shock
Solution Approach 1:
The inner housing is divided into a first housing and a second housing that are assembled together, with each housing defining specific holding portions for different components (terminals, wires, sleeve). This segmentation allows each housing to be optimized for specific holding functions, improving overall connection stability under vibration and shock while maintaining manageable structural complexity
Solution Approach 2:
Different holding portions are designed with specific local structures: the first holding portions in the second housing are configured to hold wires, while the second holding portions in both housings are configured to hold the cable sleeve. This localized optimization ensures that each component is held by the most appropriate structural features, enhancing overall reliability
2Reliability
If holding portions are added to prevent shaking, then the reliability improves, but the manufacturing precision requirements increase
Solution Approach 1:
The first holding portions and second holding portions are integrated into the housing structures during the molding process, combining the holding functions with the housing components themselves. This merging reduces the need for separate alignment procedures and reduces manufacturing precision requirements compared to adding separate holding components
Solution Approach 2:
The holding portions are pre-formed as integral parts of the housing structures during molding, rather than requiring post-assembly alignment. This preliminary formation of holding portions ensures proper positioning is achieved during the housing manufacturing process itself, reducing subsequent assembly precision requirements
Data Source
AI summary
A cable connector includes an outer housing, an inner housing including a first housing and a second housing assembled with each other, and a cable assembly retained between the first housing and the second housing. The cable assembly includes a pair of terminals, two wires, and a sleeve. The second housing defines a group of first holding portions for holding the wires. The first housing and the second housing each define a group of second holding portions for commonly holding the sleeve.