Connector With Integrated Core Fixing Portion for Vibration Blocking
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Solution Overview
Problem
Existing vibration blocking connectors in the field require complex manufacturing processes and high costs due to the need for forming flat plate welds and using separate bolts for fixation, which complicates the process and increases expenses.
Innovation Solution
A connector design that integrates a core fixing portion directly into the housing by molding, using a metal sleeve or bonded metal strands to block vibrations, simplifying manufacturing and reducing costs by eliminating the need for additional components and bolts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the end of the core and the rear end of the elastic conductor are formed into flat plate shapes and welded together with separate bolts for fixation, then vibration blocking function is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the core fixing portion and the housing into a single integrated structure formed by injection molding. The core fixing portion is directly formed within the housing body during the molding process, eliminating the need for separate welding and bolting operations. This integration resolves the technical contradiction by maintaining vibration blocking functionality while significantly simplifying the manufacturing process and reducing assembly steps.
Solution Approach 2:
The core fixing portion is pre-formed within the housing during the injection molding process before final assembly. The molding process creates the core fixing portion with embedded features that directly secure the core, eliminating the need for subsequent welding and bolting operations. This preliminary formation of the fixing structure resolves the contradiction by achieving vibration blocking without complex post-processing.
2Reliability
If flat plate welding and separate bolts are used to fix the core to the housing, then vibration transmission is blocked, but manufacturing time and cost increase
Solution Approach 1:
The patent combines multiple manufacturing operations into a single injection molding process. The core fixing portion is formed integrally with the housing in one step, eliminating the need for separate welding and bolting operations. This merging of operations resolves the technical contradiction by maintaining vibration blocking effectiveness while significantly improving manufacturing efficiency and reducing production time.
Solution Approach 2:
The injection molding process automatically forms the core fixing portion with self-securing features that directly hold the core in place. The molding process itself creates the fixing mechanism without requiring external welding or fastening operations. This self-service approach resolves the contradiction by achieving vibration blocking through the molding process alone, improving productivity.
3Reliability
If multiple separate components (core, elastic conductor, housing, bolts) are used for vibration blocking, then vibration isolation is achieved, but the number of components and manufacturing cost increase
Solution Approach 1:
The patent merges the housing and core fixing portion into a single integrated component formed by injection molding. This reduces the total number of discrete parts while maintaining the vibration blocking function through the integrated structure. The merging principle resolves the technical contradiction by eliminating the need for separate bolts and welding operations, reducing component count and manufacturing cost.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The integrated core fixing portion effectively blocks vibrations, preventing contact failures between terminal fittings while reducing manufacturing complexity and costs, and allows for efficient heat dissipation through the housing.
Implementation Method 1
Vibration that would otherwise be transmitted from the core of the coated wire to the terminal fitting is blocked in a part where the core fixing portion integrated with the core is fixed to the housing
Implementation Method 2
the core fixing portion may be formed by bonding the strands by resistance welding or ultrasonic welding
Implementation Method 3
the core fixing portion may be formed by bonding the strands by resistance welding or ultrasonic welding
Implementation Method 4
The flexible conductor may be bent to provide an extra length of the core pulled out in an exposed state from the end of the coated wire. The flexible conductor functions to absorb an assembling tolerance of housings and the like
Implementation Method 5
allows for efficient heat dissipation through the housing
Data Source
AI summary
A connector C to be mounted on a case of a device includes a coated wire 10 formed such that a core 11 is coated with an insulation coating 12, a terminal fitting 20 to be fit and connected to a mating terminal, a flexible conductor 15 interposed between the terminal fitting 20 and an end of the coated wire 10, and a housing 30 made of synthetic resin and accommodating the terminal fitting 20 together with the flexible conductor 15. The core 11 of the coated wire 10 is provided with a core fixing portion 25 integrated with the core 11 and the core fixing portion 25 is embedded in the housing 30 by molding.