Connector Dummy Wire Closure for Versatile Sealed Wire Insertion Holes
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Solution Overview
Problem
Existing connectors require redesign of dummy plugs when specifications such as dimensions or materials change, lacking versatility.
Innovation Solution
Incorporation of a lead wire and a dummy wire of the same kind, with a tubular-shaped protective tube covering them, and a U-shaped curved end of the dummy wire exposed for visual inspection, ensuring the dummy wire is inserted into empty wire insertion holes, and a waterproof member with insertable dummy wire ends to maintain watertightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dummy plug is used to close empty wire insertion holes, then foreign matter entry is prevented and reliability is improved, but redesign of the dummy plug is required whenever connector specifications change, reducing versatility
Solution Approach 1:
The invention uses a universal dummy wire that can be inserted into any empty wire insertion hole regardless of connector specifications. The dummy wire includes a terminal fitting that matches the connector's terminal fitting, allowing it to serve as a universal closure for different connector types without requiring redesign, thus maintaining reliability while improving versatility
Solution Approach 2:
The dummy wire is designed to copy the structure and dimensions of actual lead wires, including the terminal fitting interface. This allows the dummy wire to perfectly match the wire insertion holes and terminal fittings of various connectors, enabling it to function as a universal closure that prevents foreign matter entry without requiring specification-specific redesign
2Adaptability or versatility
If dummy plugs are used to close empty holes, then the connector can accommodate fewer wires than total wire insertion holes, but design changes to housing or waterproof member are required
Solution Approach 1:
The dummy wire is designed to be self-contained with its own terminal fitting that directly interfaces with the connector's terminal fitting and wire insertion hole. This self-service design eliminates the need for additional design changes to the housing or waterproof member, as the dummy wire independently provides the closure function without requiring modifications to the connector structure
Data Source
AI summary
A connection device includes a connector provided with wire insertion holes receiving end portions of electrical wires and terminal fittings connected to the end portions. The electrical wires include a lead wire and a dummy wire. One end of the lead wire is inserted in the wire insertion holes while another end of the lead wire is connected to another connector. One end and another end of the dummy wire are inserted in empty ones of the wire insertion holes. A protective tube, which is shorter than the lead wire, is provided between the connector and the other connector, so as to extend over an entire length of the lead wire except opposite end portions of the lead wire and so as to cover the lead wire and the dummy wire. A U-shaped curved end portion of the dummy wire is exposed from an end portion of the protective tube.