Connector Housing Assembly With Angled Wire Exit Routing
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Solution Overview
Problem
Conventional methods for connecting multiple technical units in complex systems require excessive numbers of electrical connectors and result in significant material, time, and space consumption due to the need for separate connectors and complex wire routing.
Innovation Solution
A housing assembly for electrical connectors with angled exit openings that allow multiple wires to be routed in different directions without splitting or threading, using a single connector with a cover element that simplifies installation and reduces the need for separate connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate connectors are used for each electrical wire in complex systems, then each target unit can be connected reliably, but the number of connectors and material consumption increases excessively
Solution Approach 1:
Multiple electrical wires are combined into a single multi-core cable that connects to a single connector housing, eliminating the need for multiple separate connectors. The connector housing integrates multiple contact elements that can each receive individual wires or bundled wires, reducing the total number of connectors while maintaining reliable connections to multiple target units.
Solution Approach 2:
The single connector housing serves multiple functions by providing multiple contact elements that can connect to different target units simultaneously. This multi-functional connector replaces what would traditionally require multiple separate connectors, reducing material consumption while maintaining connection reliability across the branched network.
2Adaptability or versatility
If electrical wires are split into multiple branches from a single connector, then multiple target units can be reached, but routing effort and space consumption increase immensely
Solution Approach 1:
Multiple electrical wires are nested together within a single multi-core cable, which is then routed through a single connector housing. This nesting approach allows multiple wires to be bundled and routed together, reducing the space required for wire routing and management compared to having separate cables for each wire, while still providing the flexibility to reach multiple target units through the branched network.
3Manufacturing precision
If wires are threaded through exit openings during installation, then proper routing is achieved, but installation time and complexity increase
Solution Approach 1:
The connector housing and cover element are designed with pre-formed exit openings that are positioned and sized to accommodate wire routing before installation. The cover element can be attached to the connector housing in advance, creating a pre-assembled unit with defined wire exit paths. During installation, wires can be simply placed into the contact elements and exit openings without requiring complex threading operations, significantly reducing installation time while maintaining precise wire routing.
Data Source
AI summary
A housing assembly for an electrical connector that is intermateable with a mating connector includes a connector housing and a cover element attachable to the connector housing, wherein the housing assembly further comprises at least two exit openings for passing electrical wires, wherein the at least two exit openings are mutually angled at 90° or more, and wherein at least one of the exit openings is jointly formed by the connector housing and the cover element. At least two wire exit directions can be accomplished due to the exit openings. An electrical connector with such a housing assembly and a connection assembly with such an electrical connector and a mating connector are provided.