Connector Fitting Force Control via Surface Geometry
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Solution Overview
Problem
Conventional connectors for wire harnesses lack a suitable feeling during fitting due to varying fitting forces caused by the shape of engagement projection parts and members, affecting the ease and reliability of connection.
Innovation Solution
A connector design featuring an engagement projection part, a separated projection part, and a fitting detection member with specific surface geometries and orientations that allow for a controlled fitting force distribution, ensuring a consistent and suitable feeling during connection by delaying the peak of the climbing force relative to the insertion force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the engagement projection part and engaged part have conventional shapes, then the connector structure is simple, but the fitting force fluctuates significantly affecting the fitting feeling
Solution Approach 1:
The engagement projection part and engaged part are designed with different local surface qualities: the climbed surface is inclined to facilitate climbing, while the climbing surface is substantially flat to provide stable engagement. This local differentiation of surface properties resolves the contradiction by optimizing each region's function rather than using a uniform complex shape.
Solution Approach 2:
The climbed surface is designed with a specific inclination angle (α) relative to the fitting direction, creating a controlled curved/angled transition rather than a sharp edge. This geometric modification allows smooth climbing force application while maintaining overall structural simplicity.
2Reliability
If the climbing surface and climbed surface are designed to delay climbing force peak, then the fitting force distribution becomes consistent, but the engagement part geometry becomes more complex
Solution Approach 1:
The inclination angle (α) of the climbed surface is controlled within a specific range (5° to 45°) to optimize the force distribution characteristics. By adjusting this geometric parameter within defined bounds, the patent achieves consistent fitting force distribution without requiring complex multi-dimensional geometries.
Solution Approach 2:
The engagement surfaces are segmented into distinct functional zones: the climbed surface with inclination for force distribution control, and the climbing surface that is substantially flat for stable engagement. This segmentation allows each zone to perform its specific function independently, achieving reliable force distribution with simple geometric elements.
3Ease of operation
If the tip end projection faces the engagement projection part after terminal connection starts, then the fitting force fluctuation is reduced, but the engagement part design becomes more complex
Solution Approach 1:
The tip end projection is positioned to face the engagement projection part before the climbing force is fully applied. This preliminary positioning ensures that the fitting force is distributed evenly from the beginning of the engagement process, preventing sudden force fluctuations and providing stable fitting feeling throughout the connection.
Data Source
AI summary
In the connector, a female beak of a female housing includes a climbing surface formed on an end part at a removing direction side, and a tip end projection that protrudes in a removing direction from an end part at an upper direction side of the climbing surface. A male beak of a male housing includes a climbed surface formed on an end part at an inserting direction side, and that comes into contact with the climbing surface in a fitting direction. After connection of a male terminal housed in the male housing with a female terminal housed in the female housing is started, a tip end projection faces the male beak in a vertical direction. After the tip end projection faces the male beak, the climbing surface comes into contact with the climbed surface.