Connector Coupling Projections Stabilize Terminal Against Wire Pull
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Solution Overview
Problem
Existing connectors are prone to deformation or breakage when the wire connected to the terminal fitting is pulled, as the coupling mechanism is not adequately secured to resist directional loads.
Innovation Solution
A connector design featuring a plate-like coupling with projections that contact an inner groove in the housing, preventing deformation or breakage by stabilizing the terminal fitting during wire pull, and a locking mechanism that suppresses displacement in multiple directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the coupling is made simple and flexible to connect terminal and wire, then ease of manufacture and assembly is improved, but the coupling becomes prone to deformation or breakage when wire is pulled
Solution Approach 1:
The coupling is divided into multiple portions (first coupling portion connected to terminal, second coupling portion connected to wire) with distinct functions. Each portion can be optimized independently - the first portion integrates with terminal structure while the second portion interfaces with wire, allowing specialized design for each connection type and improving overall reliability without complicating manufacturing
Solution Approach 2:
The coupling portions are integrated into the housing structure through grooves and recesses. The first coupling portion is received in a groove formed in the housing, and the second coupling portion extends into the wire connecting portion. This nesting approach allows the coupling to be securely positioned within the housing while maintaining a compact, integrated design that does not increase manufacturing complexity
2Reliability
If the coupling structure is reinforced to prevent deformation when wire is pulled, then reliability is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The coupling portions are merged with the housing structure through integrated grooves and recesses. The housing itself provides structural support through its groove formations, eliminating the need for separate reinforcement elements. The coupling portions are not standalone components but are integrated into the housing, reducing overall device complexity while maintaining reliability
Solution Approach 2:
The housing serves multiple functions: it provides structural support, contains the coupling portions through integrated grooves, and positions both the terminal and wire connecting portions. The groove structure simultaneously acts as a mounting feature and a reinforcement element, reducing the need for additional components and simplifying the overall device design
3Volume of moving object
If the terminal and housing size are reduced for compactness, then volume is improved, but the coupling may have insufficient space to resist pull forces on the wire
Solution Approach 1:
The coupling portions extend in multiple directions - the first coupling portion extends in a first direction from the terminal, while the second coupling portion extends in a second direction toward the wire connecting portion. This multi-directional arrangement allows the coupling to resist pull forces effectively while maintaining a compact overall volume, as the strength is distributed across different spatial dimensions rather than requiring a large single-direction structure
Data Source
AI summary
A connector (10) includes terminals (14) and a housing (12) with terminal accommodating portions (36) to accommodate the terminals (14). Each terminal (14) includes a terminal connecting portion (18) extending in a front-rear direction and a vertical wire connecting portion (20) perpendicular to the front-rear direction. A first coupling portion (22A) extends in the front-rear direction from a rear end of the terminal connecting portion (18), and a second coupling portion (22B) extends vertically from an extending end of the first coupling (22A) to the wire connecting portion (20). Projections (30) project from sides of the first coupling portion (22A) in a third direction perpendicular to the front-rear direction and the vertical direction. Grooves (42) are open in inner walls (38A) of the terminal accommodating portion (36) facing each other in the third direction, and the projections (30) contact inner walls of the grooves (42) in the vertical direction.