Connector With Electronic Component Preventing Lead Wire Rotation
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Solution Overview
Problem
Existing connectors with built-in electronic components, such as capacitors, face challenges in preventing rotation during installation, which complicates the process and increases costs due to the need for complex dies and potential wire collisions.
Innovation Solution
A connector design featuring a holder with a projection on the lead wire that radially extends from the electronic component, guided by a groove in the holder to suppress circumferential movement and facilitate positioning, ensuring easy insertion and preventing collisions with the holder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an insertion hole is formed in the back wall of the capacitor holder to guide the lead wire, then the lead wire can be connected to the terminal, but the device complexity increases due to requiring a complicated die and the manufacturing cost increases
Solution Approach 1:
The guide is formed as an integral part of the holder structure before the lead wire insertion process. The guide pre-defines the insertion path and positioning, eliminating the need for complex dies during the actual assembly operation. This preliminary structuring of the guidance function into the holder itself resolves the contradiction by simplifying the operational process without requiring complex manufacturing tools.
2Ease of operation
If the capacitor is inserted without rotation prevention, then the insertion process is simpler, but the capacitor may rotate causing the lead wire to contact the back wall or fail to insert properly
Solution Approach 1:
The guide acts as an intermediary element between the lead wire/projection and the holder. It provides a controlled interface that allows smooth insertion while simultaneously preventing rotation through its geometric constraints. The guide mediates the insertion process by defining both the path and the orientation, resolving the contradiction between ease of operation and insertion reliability.
3Device complexity
If the lead wire is inserted without a guide, then the device structure is simpler, but the lead wire may collide with the holder or fail to reach the terminal
Solution Approach 1:
The guide is implemented as a localized feature within the holder structure rather than a complete redesign of the entire holder. By concentrating the guidance and positioning function in a specific local region (the guide channel), the overall device complexity remains low while providing the necessary lead wire positioning and collision prevention functions.
Data Source
AI summary
A connector includes a holder (20) and an electronic component (60) with a cylindrical main body (61). Lead wires (62) project axially from one axial end (61A) of the main body (61). An electronic component holding portion (35) is in the holder (20) and includes an insertion opening (39) into which the electronic component (60) is inserted. Projecting portions (64) are formed on the lead wires (62) and project radially out beyond an outer peripheral surface of the main body (61). The electronic component holding portion (35) includes a main body accommodating portion (36) for accommodating the main body (61) and guides (37) that communicate with the main body accommodating portion (36). The guides (37) are located radially outward of the main body (61) and guide the projecting portions (64) toward back sides in an inserting direction while suppressing circumferential movements of the projecting portions (64).