Connector With Identical Inner Housings and Distinct Outer Housings
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Solution Overview
Problem
The existing connector designs face increased costs due to the need for different shapes of housings for force multiplying mechanisms and manual fitting, which prevents part sharing and leads to inefficiencies in production.
Innovation Solution
A connector design featuring identically shaped inner housings and differently shaped outer housings, with the first housing using a lock arm for fitting and the second housing using a lever with cam action for connecting, allowing for minimal cost increase by eliminating the need for levers on the first housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the first housing includes a force multiplying mechanism such as a lever to enable fitting into the first fitting recess, then the connecting operation can be performed with minimal operating force, but the first and second housings have different shapes which prevents part sharing and increases cost
Solution Approach 1:
The housing is divided into two separate components: an inner housing that fits into the fitting recess and an outer housing that provides the force multiplying mechanism. This segmentation allows the inner housing to be identical in both connectors while the outer housings can differ, resolving the contradiction between operational ease and manufacturing efficiency.
Solution Approach 2:
The outer housing acts as an intermediary between the user's manual operation and the inner housing fitting process. It provides the lever mechanism that amplifies operating force, while the identical inner housings maintain manufacturing efficiency through part sharing.
2Ease of manufacture
If the first and second housings are made identically shaped to enable part sharing, then manufacturing cost is reduced, but the first housing cannot utilize a force multiplying mechanism if manual fitting is sufficient for the second housing
Solution Approach 1:
By separating the housing into inner and outer components, the design allows identical inner housings to be used in both connectors for cost-effective manufacturing, while the outer housings can be customized with or without force multiplying mechanisms based on operational requirements.
Solution Approach 2:
The force multiplying mechanism is applied locally only where needed (first connector) rather than universally. The outer housing of the first connector includes the lever mechanism, while the outer housing of the second connector can be simpler, allowing part sharing for the inner housings while maintaining operational appropriateness.
3Adaptability or versatility
If different holding means are used for the first and second outer housings to accommodate different operating conditions, then functional requirements are met, but the outer housings must have different shapes which increases part cost
Solution Approach 1:
The separation into inner and outer housings allows the outer housings to differ in design (with or without force multiplying mechanisms) while the inner housings remain identical, reducing overall part cost while maintaining adaptability to different operating conditions.
Solution Approach 2:
The inner housing design serves as a universal component that can be used in both connectors, while the outer housing provides the specific functional adaptation needed for each operating condition. This multi-functionality approach reduces the total number of unique parts required.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design allows for cost-effective production by enabling part sharing between inner housings while enabling efficient connecting operations with minimal operating force, thus reducing overall costs and maintaining functionality.
Implementation Method 1
the second holding means comprises a lever which displays a cam action between the lever and the intermediate housing to proceed with a connecting operation by being displaced relative to the second fitting recess
Implementation Method 2
the first holding means comprises a lock arm for resiliently locking a lock portion provided on or at the first fitting recess at the time of proper connection
Data Source
AI summary
A connector includes an intermediate housing (10) with a first fitting recess (12) and a second fitting recess (13), a first inner housing (30A) to be fitted into the first fitting recess, a first outer housing (50) separate from the first inner housing (30A) and to be externally fitted onto the first fitting recess (12), a second inner housing (30B) to be fitted into the second fitting recess (13), and a second outer housing (70) separate from the second inner housing (30B) and to be externally fitted onto the second fitting recess (13). The first and second outer housings (50, 70) are shaped differently from each other and the first and second inner housings (30A, 30B) are identically shaped.