Integrally Molded Cable Holder Connector Design
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Solution Overview
Problem
Existing connectors for electrically connecting flat cables and circuit boards require multiple assembly steps and are prone to cable disconnection due to the separate holder and socket components, leading to inefficiency and potential mechanical failure.
Innovation Solution
A connector design where the holder is integrally molded with the cable, featuring a base portion embedding the insulating coat and conductor, and an extension portion covering the conductor to engage directly with the socket, reducing the number of components and enhancing holding force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a one-piece holder structure is employed, then the number of assembly steps is reduced and yield is improved, but the holding force and connection reliability may be insufficient
Solution Approach 1:
The holder is divided into a base portion and an extension portion that are integrally molded together. The base portion embeds the cable (insulating coat and conductor) to provide strong holding force, while the extension portion extends toward the socket to ensure reliable engagement. This segmentation allows each part to optimize its function while maintaining integral construction for assembly efficiency.
2Reliability
If the holder is integrally molded with the cable, then the holding force is increased and cable disconnection is prevented, but the manufacturing complexity increases
Solution Approach 1:
The base portion of the holder and the cable (insulating coat and conductor) are integrally molded as a single structure. This merging eliminates the need for separate assembly steps to attach the cable to the holder, thereby increasing holding force and preventing cable disconnection while managing manufacturing complexity through a unified molding process.
3Reliability
If the extension portion covers the conductor, then the electrical contact reliability is improved, but the number of components increases
Solution Approach 1:
The extension portion is integrally molded with the base portion, forming a single holder structure that covers and protects the conductor. This merging ensures reliable electrical contact by properly positioning and protecting the conductor while avoiding the need for additional separate components, thus maintaining assembly efficiency.
Data Source
AI summary
A connector (1) according to the present disclosure includes a holder (10) holding a cable (30) including a conductor (31) and an insulating coat (32) covering the conductor (31), and a socket (20) with which the holder (10) is to be engaged and including a contact (22). The holder (10) includes a base portion (11) holding the cable (30) by being integrally molded with the cable (30) and in which a portion of each of the insulating coat (32) and the conductor (31) of the cable (30) is embedded, and an extension portion (12) covering at least a portion of the conductor (31) and extending from the base portion (11) toward a side of connect with the socket (20). The holder (10) exposes a part of the conductor (31) of the cable (30) in contact with the contact (22) in an engaged state in which the holder (10) and the socket (20) are engaged with each other.