Connector Guide Portion for Insertion Alignment
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Solution Overview
Problem
The existing connector design with a closed guide hole structure can lead to difficulties in inserting a male contact due to manufacturing variations, causing positional differences between the guide hole and the receiving portion.
Innovation Solution
The connector design includes an open insertion opening with a guide portion on the protection portion of the female contact, ensuring the male contact is guided into the receiving portion without obstruction, even with positional differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a closed guide hole structure is used in the insulator, then the protection portion can prevent the contact spring piece from deforming, but the male contact cannot be inserted into the receiving portion when positional differences occur due to manufacturing variation
Solution Approach 1:
The guide hole structure is segmented into two functional zones: an upper closed portion that provides protection and guidance, and a lower open portion that allows insertion. This segmentation resolves the contradiction by separating the protective function from the insertion function, allowing each to operate independently without interference.
Solution Approach 2:
Different portions of the guide hole have different structural qualities - the upper portion is closed to provide protection and guidance, while the lower portion is open to facilitate insertion. This local differentiation of structural properties allows the same component to fulfill multiple contradictory requirements simultaneously.
2Manufacturing precision
If the guide hole is closed to protect the contact spring piece, then deformation is prevented, but manufacturing variations cause misalignment between the guide hole and receiving portion
Solution Approach 1:
The guide hole is divided into a closed upper portion for precise alignment and protection, and an open lower portion that accommodates manufacturing variations. This segmentation allows the critical alignment function to be isolated to the upper portion while the lower portion provides tolerance for variation.
Solution Approach 2:
The open lower portion of the guide hole acts as a cushioning zone that absorbs positional deviations caused by manufacturing variations before they affect the critical alignment between the contact spring piece and receiving portion, thereby maintaining reliability despite imprecision.
3Ease of operation
If the guide hole is opened to allow easy insertion, then male contact can be inserted even with positional differences, but the protection portion may obstruct insertion
Solution Approach 1:
The guide hole structure is segmented to separate the protection function (upper closed portion) from the insertion function (lower open portion). This allows the protection portion to maintain its protective role while the open lower portion ensures easy insertion, reducing the need for additional protective structures.
4Object-affected harmful factors
If a closed entry structure is used, then the contact spring piece is protected from external factors, but manufacturing variations prevent proper insertion of the male contact
Solution Approach 1:
The guide hole is segmented into a closed upper portion that protects from external factors and provides precise positioning, and an open lower portion that tolerates manufacturing variations. This segmentation allows the system to maintain protection while accommodating imprecision.
Solution Approach 2:
The open lower portion serves as a cushioning zone that absorbs positional errors from manufacturing variations before they reach the protected contact spring piece, allowing the closed upper portion to maintain its protective function without requiring high manufacturing precision.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A connector is provided with a female contact and a housing. A protection portion of the female contact has a guide portion intersecting with a front-rear direction to guide a male contact to a receiving portion. An insertion opening of the housing is located forward of a contact accommodation portion in the front-rear direction. The insertion opening opens in a predetermined direction perpendicular to the front-rear direction and thereby communicates with an aperture portion. When a front of the connector is viewed along the front-rear direction, the guide portion is visible through the insertion opening at least in part.