Connector Housing Cavity Shape for Easier Seal Wire Insertion
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Solution Overview
Problem
There is a need for ease of insertion of a sealing member-equipped electric wire into a connector housing, as existing technologies face challenges in facilitating this process.
Innovation Solution
A connector housing design featuring a cavity with specific portions: a first portion with a polygonal horizontal cross-section, a second portion with another opening, a third portion with a circular cross-section smaller than the first portion, and an optional fourth portion for gradual deformation, which reduces friction and contact points, making it easier to insert the sealing member-equipped electric wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sealing member is attached to a terminal-equipped electric wire, then sealing function is improved, but insertion difficulty increases due to friction and contact resistance
Solution Approach 1:
The cavity is divided into three distinct portions: a first portion with a large polygonal cross-section for easy entry, a third portion with a smaller circular cross-section for proper positioning, and a second portion connecting them. This segmentation allows the sealing member-equipped electric wire to be inserted smoothly while maintaining sealing reliability.
Solution Approach 2:
Different portions of the cavity have different cross-sectional characteristics tailored to specific functions: the first portion has a large polygonal cross-section to reduce insertion resistance, the third portion has a smaller circular cross-section for precise positioning, and the second portion provides the transition. This local quality differentiation resolves the contradiction between sealing reliability and insertion ease.
2Ease of manufacture
If the cavity cross-section is uniform, then manufacturing is simplified, but insertion of sealing member-equipped electric wire becomes difficult
Solution Approach 1:
The cavity is segmented into three portions with different cross-sectional characteristics. While this increases manufacturing complexity compared to a uniform cavity, the segmentation is achieved through a continuous varying cross-section that can be manufactured using standard molding techniques, balancing manufacturing simplicity with insertion ease.
Solution Approach 2:
The cross-sectional parameters of the cavity (area, shape) are changed along its length to optimize both manufacturing and insertion. The cross-section transitions from a large polygonal shape at the first portion to a smaller circular shape at the third portion, with the second portion providing a gradual transition. This parameter change allows the cavity to be manufactured with standard techniques while significantly improving insertion ease.
Data Source
AI summary
It is an object of the present disclosure to provide a technique for facilitating the insertion of a sealing member-equipped electric wire into a connector housing. The connector housing includes: a housing main body that is provided with a cavity. The cavity includes a first portion that includes one opening portion of the cavity, a second portion that includes the other opening portion of the cavity, and a third portion that is located between the first portion and the second portion. The first portion has a polygonal horizontal cross section, and the third portion has a circular horizontal cross section that is smaller than the horizontal cross section of the first portion.