Flexible Locking Element for Connector Assembly Vibration
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Solution Overview
Problem
Existing joint connectors for vehicle wiring harnesses face challenges in easy assembly and disassembly, secure fixing, and reduction of vibration-induced noise, often requiring costly rigid materials to prevent component separation.
Innovation Solution
A joint connector design featuring a cap, plug, and clip with a flexible locking element that securely fixes all components together, using a flexible material for the cap and plug to reduce manufacturing costs and enhance engagement, while a bounce part and inclined portion ensure secure mounting and vibration reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid materials are used to prevent component separation, then fixing performance is improved, but manufacturing costs increase
Solution Approach 1:
The patent changes the material parameter from rigid to flexible, specifically using a flexible locking element made of elastomer or rubber material. This flexible material provides sufficient fixing performance through elastic deformation and locking action while being more cost-effective than rigid materials, directly resolving the contradiction between fixing performance and manufacturing cost
Solution Approach 2:
The patent employs composite material construction where the locking element is made of flexible material (elastomer/rubber) integrated with the plug body. This composite approach combines the structural support of the rigid plug housing with the flexible locking properties of the elastomer material, achieving reliable fixing at lower cost
2Ease of manufacture
If flexible material is used for cap and plug, then manufacturing cost is reduced, but engagement security may worsen
Solution Approach 1:
The patent changes the material parameter of the locking element to flexible material (elastomer or rubber) while maintaining engagement security through the designed locking mechanism. The flexibility allows the locking element to deform during assembly and then lock securely, providing both cost benefits and reliable engagement
Solution Approach 2:
The locking element features a curved locking surface that engages with corresponding surfaces on the cap and housing. This curved geometry, combined with the flexible material, creates a secure locking action that prevents disengagement while using cost-effective flexible materials
3Ease of operation
If clip is engaged with connector housing, then assembly is simplified, but vibration and noise occur due to gaps
Solution Approach 1:
The patent merges the functions of the locking mechanism into a single integrated locking element that simultaneously secures both the cap and the clip to the housing. This unified locking action eliminates gaps between components, preventing vibration and noise while maintaining simple assembly through the single-piece locking element design
Solution Approach 2:
The patent changes the material parameter to flexible material for the locking element, which allows the component to conform precisely to the housing and cap surfaces. This eliminates gaps that would cause vibration and noise, while the flexible nature maintains ease of assembly through elastic deformation during installation
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 design allows for easy assembly and disassembly, reduces noise from vibration, and lowers manufacturing costs by using cost-competitive flexible materials, providing improved fixing performance and preventing component separation.
Implementation Method 1
The plug includes a flexible locking element fixing the cap and the clip simultaneously
Implementation Method 2
a bounce part and inclined portion ensure secure mounting and vibration reduction
Data Source
AI summary
A joint connector includes a cap, a plug received in the cap in a mounting direction, and a clip mounted along the mounting direction to fix the cap and the plug, wherein the plug comprises a flexible locking element configured to simultaneously fix the cap and the clip. The locking element is connected to the plug deformably in a vertical direction with respect to the plug.