Circular Protective Cap for Grommet Installation
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Solution Overview
Problem
Existing protective caps with a quadrangular tube shape often get stuck in the bellows-shaped tubular portion of a grommet when passing a male connector housing with attached male terminals and electric wires, potentially damaging the grommet during installation.
Innovation Solution
A protective cap with a circular cap main body and an accommodating recessed portion that fits the tab portions of the male terminals, having an outer diameter smaller than the grommet's inner diameter, allowing the male inner housing with attached terminals and wires to pass through smoothly without getting caught.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a quadrangular tube-shaped protective cap is used, then the cap can accommodate tab portions of male terminals, but the cap gets stuck in the bellows-shaped tubular portion of the grommet during installation
Solution Approach 1:
The protective cap is changed from a quadrangular tube shape to a substantially cylindrical shape. This curved, circular cross-section allows the cap to easily pass through the bellows-shaped tubular portion of the grommet without getting stuck, as the rounded form can navigate the flexible, corrugated passage smoothly.
2Ease of operation
If the protective cap is made cylindrical with smaller outer diameter, then it passes through the grommet smoothly, but the accommodation capability for multiple terminals must be maintained
Solution Approach 1:
The cylindrical protective cap incorporates an accommodating recessed portion that can nest multiple tab portions of male terminals within its structure. The recessed portion is formed with multiple cavities or compartments that can hold different terminals, allowing the cap to accommodate multiple components while maintaining its streamlined cylindrical exterior that fits through the grommet.
Data Source
AI summary
A protective cap is used when a male inner housing to which male terminals and electric wires are attached is passed through a bellows-shaped tubular portion of a grommet. A male outer housing mounted on an annular seal portion of the grommet and the male inner housing accommodated in the male outer housing in a state where the male inner housing accommodates and holds the male terminals connected to the electric wires constitutes the connector. The protective cap includes a circular cap main body having an accommodating recess that accommodates tab portions of the male terminals protruding more than a front face of the male inner housing, at least a front side of the male inner housing being fitted into the accommodating recess. An outer diameter of the cap main body is smaller than an inner diameter of the bellows-shaped tubular portion.