Integrated Connector Housing for Precise Terminal Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connectors face issues with relative positional deviation of terminals held by movable housings, breakage of restraint space forming portions, and inability to downsize in the arrangement direction due to separate terminal holding portions and separate bodies in the fixing housing.
Innovation Solution
The connector integrates the terminal holding portions of the fixing housing with resin, incorporates an intermediate connection portion to restrict movable housing movement, and includes a restraint space forming portion with a top wall and reinforcing wall to prevent deviation and breakage, allowing for downsizing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate terminal holding portions are used in the fixing housing, then manufacturing flexibility is improved, but relative positional deviation of terminals occurs
Solution Approach 1:
The patent merges multiple terminal holding portions into a single integrally molded resin component. The fixing housing includes multiple terminal holding portions (first terminal holding portion, second terminal holding portion, etc.) that are formed as one integrated structure through resin molding, eliminating the need for separate components and ensuring precise relative positioning of terminals while maintaining manufacturing efficiency.
2Ease of operation
If separate bodies are used in the fixing housing, then assembly flexibility is improved, but structural integrity deteriorates
Solution Approach 1:
The fixing housing is designed as an integrally molded resin structure that combines multiple functional elements (terminal holding portions, restraint space forming portions, connection portions) into a single unified component. This integration maintains structural integrity and strength while allowing flexible assembly of the connector system through the inherent modularity of the integral design.
Solution Approach 2:
The patent utilizes resin material with composite properties that provide both the necessary structural strength and flexibility for the fixing housing. The resin material enables the integrally molded structure to maintain rigidity where needed while allowing for the designed movement and assembly flexibility of the connector components.
3Volume of moving object
If restraint space forming portion has thin walls, then connector size is reduced, but breakage resistance deteriorates
Solution Approach 1:
The restraint space forming portion is designed with non-uniform wall thickness, featuring thin walls in non-critical areas to minimize overall connector size while incorporating locally reinforced sections with increased thickness in areas subject to stress and movement. This localized reinforcement prevents breakage at critical points while maintaining compact dimensions throughout the structure.
Solution Approach 2:
The restraint space forming portion includes designed clearance and movement tolerance that accommodates the natural movement of the movable housing before contact occurs. This pre-planned clearance prevents excessive stress concentration on the walls during operation, reducing the risk of breakage even with thinner wall sections.
4Manufacturing precision
If movable housing movement is restricted, then terminal positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The movement restriction function is integrated into the fixing housing structure itself through the restraint space forming portion, rather than being implemented as a separate mechanism. The restraint space with its specifically designed geometry inherently limits the movable housing movement to predetermined ranges, achieving precise terminal positioning while maintaining结构简单性 through the integral design.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
When a first movable housing and a second movable housing are provided, relative positions of a first terminal and a second terminal are prevented from deviating from predetermined positions. A connector 1 includes a fixing housing 2, a first movable housing 31, a second movable housing 32, a first terminal 41, and a second terminal 42. The fixing housing 2 includes the first terminal holding portions 21A that hold the first fixing-side held portions 4B of the first terminals 41, and the second terminal holding portions 22A that hold the second fixing-side held portions 4B of the second terminals 42. The first terminal holding portion 21A and the second terminal holding portion 22A of the fixing housing 2 are integrally molded with resin.