Two-Material Connector Housing for Lightweight Structural Stability
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Solution Overview
Problem
Existing connectors face limitations in weight reduction due to the constraints of forming lightening recesses, which may not allow for sufficient volume reduction, thereby hindering further weight optimization.
Innovation Solution
A connector design incorporating a housing made of two distinct synthetic resin materials, where a first function portion is made of a flexible material with a higher specific weight and a second function portion is made of a lighter material, integrated through two-color molding, with anchor portions to maintain structural integrity and reduce weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If lightening recesses are formed in the housing for weight reduction, then the weight is reduced to some extent, but the weight reduction is limited and sufficient weight reduction cannot be realized when the housing shape does not allow for multiple or large-volume lightening recesses
Solution Approach 1:
The patent changes the material parameter (specific weight) of the housing portions instead of changing the geometric parameter (forming recesses). By using a synthetic resin material with smaller specific weight for the second function portion, significant weight reduction is achieved without being constrained by housing shape or manufacturing limitations of recesses.
Solution Approach 2:
The patent applies composite material construction by combining two different synthetic resin materials with different specific weights in the housing. The first function portion uses a flexible synthetic resin material while the second function portion uses a lighter synthetic resin material, achieving overall weight reduction while maintaining structural integrity and functionality.
2Weight of moving object
If the housing is made entirely of lightweight material, then weight reduction is maximized, but structural integrity and flexibility requirements cannot be met
Solution Approach 1:
The patent applies local quality by assigning different material properties to different functional portions of the housing. The first function portion requiring flexibility is made of flexible synthetic resin material, while the second function portion where weight reduction is prioritized is made of lighter synthetic resin material. This ensures each portion has the appropriate material properties for its specific function.
Solution Approach 2:
The patent uses composite material construction combining flexible synthetic resin material for structural portions requiring flexibility and lighter synthetic resin material for portions where weight reduction is the priority. This composite approach maintains overall structural integrity and flexibility while achieving significant weight reduction.
Data Source
AI summary
A connector (A) is provided with a terminal fitting (10) and a housing (20) for holding the terminal fitting (10). The housing (20) includes a first function portion (30) made of a flexible synthetic resin material and a second function portion (32) made of a synthetic resin material having a smaller specific weight than the first function portion (30). The connector (A) is lighter by a weight obtained by multiplying a specific weight difference of the first function portion (30) and the second function portion (32) by a volume of the second function portion (32) as compared to a connector in which the entire housing (10) is made of the same material as the first function portion (30).