Connector Housing with Tilted Supporting Surfaces for Vibration Resistance
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Solution Overview
Problem
Existing connectors for connecting power cables to boards in electronic vehicles require significant installation space and lack durability and safety due to limited space constraints and exposure to vibrations, which can lead to disconnection.
Innovation Solution
A connector design featuring a housing with supporting surfaces that form a retaining portion to secure the contact crimped onto the power cable, allowing for a form-locking mechanism with minimal space usage, ensuring the contact is aligned and fixed within the connector, and utilizing guiding posts and leg supports for secure mounting within a casing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a conventional connector design is used, then the connection is secure and durable, but the installation space required is large
Solution Approach 1:
The contact is nested within a retaining portion formed by supporting surfaces in the housing. The upper area of the contact is retained between multiple supporting surfaces (first, second, third, and fourth supporting surfaces) that are integrated into the housing structure, allowing the contact to be securely held within a compact volume without requiring additional external retaining components.
Solution Approach 2:
The housing is designed to be longer along the longitudinal axis of the contact than transverse to said axis, utilizing the longitudinal dimension for the form-locking mechanism. This dimensional orientation allows the second housing part to be bent towards the first housing part to engage in a form-locking manner, achieving secure connection within minimal transverse space.
2Volume of moving object
If the connector is designed for compact installation, then the space usage is reduced, but the connection may disconnect under vibrations
Solution Approach 1:
The second housing part is designed to be bendable towards the first housing part to engage in a form-locking manner. This dynamic engagement mechanism allows the housing parts to flex and lock together, creating a vibration-resistant connection that maintains reliability while occupying minimal installation space.
Solution Approach 2:
The multiple supporting surfaces are positioned to enclose and support the contact at critical points before vibration forces can cause disconnection. The first, second, third, and fourth supporting surfaces work together to pre-position and secure the contact, preventing movement that could lead to disconnection under vibrational stress.
3Reliability
If the contact is securely retained with multiple supporting surfaces, then the connection reliability is improved, but the device complexity increases
Solution Approach 1:
Multiple supporting surfaces (first, second, third, and fourth supporting surfaces) are merged into the housing structure itself rather than being separate components. The first housing part contains first and second supporting surfaces, while the second housing part contains third and fourth supporting surfaces, integrating the retention function into the housing walls to reduce overall device complexity.
Solution Approach 2:
The housing parts serve multiple functions: they provide structural enclosure, contain the contact, provide electrical connection paths, and enable form-locking engagement. The supporting surfaces simultaneously support the contact, align it with connecting openings, and prevent disconnection under vibration, reducing the need for additional specialized components.
Data Source
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AI summary
A connector for connecting a power cable to a board has a housing adapted to hold a contact which is crimpable onto the power cable. The housing comprises a first housing part (23) and a second housing part (24) formed as one piece. The first housing part (23) has a retaining portion (28) for retaining a lower area of the contact and a first supporting portion (29) for supporting an upper area of the contact transverse to a longitudinal axis of the contact. The second housing part (24) comprises a second supporting portion adapted to interact with the first supporting portion such that the upper area of the contact is retained therebetween. The second housing part (24) is bendable towards the first housing part (23) to engage therewith in a form locking manner. The first supporting portion comprises a first supporting surface (35) and a second supporting surface (36) which are tilted relative to each other. The second supporting portion comprises a third supporting surface and a fourth supporting surface which form a corresponding counterpart to the first supporting (35) surface and the second supporting surface (36) such that the upper part of the contact is retained between at least the first, second, third and fourth supporting surface (35, 36) when the second housing part (24) engages with the first housing part (23).