Connector With Aligning Member For Relay Wire Assembly
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Solution Overview
Problem
Existing connectors require retainer and housing configurations at both ends of electrical wires, making it difficult to accurately and efficiently insert terminals into housings, especially when used with relay wires having terminals on both ends.
Innovation Solution
A connector design featuring a first and second housing with terminals connected at both ends of a flexible member, utilizing an aligning member with a flexible member insertion cavity to facilitate easy and accurate insertion of terminals into the housings, allowing for a movable aligning member to position and secure the terminals within the housings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If retainer and housing configurations are used at both ends of electrical wires, then the connector can be assembled with terminals on both ends, but the assembly process becomes complex and time-consuming
Solution Approach 1:
A guide member is introduced as an intermediary component between the first housing and second housing. The guide member includes a guide hole through which the flexible member passes, and positioning protrusions that engage with positioning recesses in the housings. This intermediary structure simplifies the assembly process by providing a single coordinated mechanism for aligning and securing both terminals, rather than requiring separate retainer and housing operations at each end.
2Reliability
If traditional housing and retainer structures are used, then terminals can be secured, but the insertion process lacks precision and requires more time
Solution Approach 1:
The guide member is pre-configured with positioning protrusions that correspond to positioning recesses in the housings before assembly begins. The guide hole is pre-formed at the correct position and orientation. During assembly, these pre-configured features automatically align the flexible member and terminals with the housings as the guide member is inserted, eliminating the need for manual alignment operations and reducing assembly time while ensuring precise positioning.
3Ease of manufacture
If separate retainer and housing operations are performed at each end, then terminals can be individually secured, but the overall assembly complexity increases
Solution Approach 1:
The guide member combines multiple functions into a single component: it provides structural support, defines the insertion path through the guide hole, and ensures precise positioning through its protrusions that engage with housing recesses. This merged structure eliminates the need for separate retainer components at each end, simplifying the overall device while maintaining ease of terminal insertion.
Data Source
AI summary
A connector 10 includes: a first housing 11A, a first terminal 51A attached to the first housing 11A; a second housing 11B separate from the first housing 11A; a second terminal 51B attached to the second housing 11B; a flexible member 81 where the first terminal 51A and second terminal 51B are connected to two ends, and connecting the first housing 11A and second housing 11B; and an aligning member 41 having a flexible member insertion cavity 44 where the flexible member 81 is inserted, and that is movably arranged between the first housing 11A and second housing 11B in a condition where the flexible member 81 is inserted.