Compact Connector Housing With Internal Wiring Board and Continuity Check
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Solution Overview
Problem
Conventional insulation displacement connectors are bulky due to the external arrangement of wiring, and there is a need for improved convenience in confirming electrical continuity between devices and wiring.
Innovation Solution
A connection instrument with a housing that integrates a wiring board, where connection terminals and parts are arranged to reduce size and prevent damage, featuring metal pieces with notches to pinch core wires for enhanced reliability, and includes electronic components for continuity detection and signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wiring is arranged outside the connector housing and insulation displacement terminal protrudes out, then connection to core wire is achieved, but overall size of the connector increases
Solution Approach 1:
The patent integrates the insulation displacement terminal within the connector housing, nesting the terminal structure inside the housing rather than having it protrude outward. This allows the terminal to perform insulation displacement function while maintaining a compact overall connector size, as the terminal is housed within the housing boundaries.
Solution Approach 2:
The patent repositions the insulation displacement terminal from a protruding external arrangement to an internal arrangement within the housing, effectively changing the spatial dimension of the terminal's location. This dimensional reorganization allows the terminal to function while the connector maintains a compact footprint.
2Volume of moving object
If connection terminal and wiring board are integrated in housing, then size is reduced, but arrangement space for electronic components is limited
Solution Approach 1:
The patent segments the housing into distinct functional zones: one area for the integrated wiring board with connection terminals, and another area for arranging electronic components. This spatial segmentation allows both the integrated connection structure and electronic components to coexist within the compact housing without interfering with each other.
Solution Approach 2:
The patent applies local quality by creating different functional regions within the housing with different spatial characteristics. The wiring board area is optimized for electrical connections, while the electronic component area provides adequate mounting space, allowing each region to serve its specific function effectively within the compact overall structure.
3Reliability
If terminal position and connection part position coincide perpendicular to insertion direction, then force during insertion is prevented, but thickness of connector increases
Solution Approach 1:
The patent employs asymmetric positioning where the terminal and connection part are aligned in the insertion direction but deliberately offset in the perpendicular direction. This asymmetric arrangement allows the terminal to engage the connection part smoothly during insertion without generating lateral forces, while the offset positioning prevents the need for increased thickness to accommodate both elements.
4Reliability
If notch pinches core wire perpendicularly, then insulation cutting and electrical connection reliability are improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the insulation cutting function and the electrical connection function into a single integrated notch structure on the connection terminal. This unified design performs both functions simultaneously during one insertion action, eliminating the need for separate insulation cutting and connection operations, thereby reducing overall manufacturing complexity while maintaining high connection reliability.
Data Source
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AI summary
A connection instrument includes: a cable (10) including an electrical wire (11A, 11B) and two covering parts (12A, 12B) that cover the electrical wire and are separated from one another; a connection terminal (30A, 30B) connectable to a terminal of an external connector; a connection part (31A, 31B); a flat plate-shaped wiring board (40); and a housing. The connection part (31A, 31B) electrically connects the connection terminal (30A, 30B) and the electrical wire (11A, 11B) exposed between the two separated covering parts (12A, 12B). The connection terminal (30A, 30B) and connection part (31A, 31B) are arranged on the wiring board (40). The wiring board (40) is located between the two covering parts (12A, 12B). The housing allows insertion/extraction of the external connector and houses the wiring board (40). At least part of the wiring board (40) is roughly in contact with or included in a space linking adjacent ends of the two covering parts (12A, 12B).