Connector Insert Stabilizer for Automotive Wire Protection
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Solution Overview
Problem
Two-conductor systems in automobiles are prone to breakdown at plug connections due to mechanical stress and exposure of conductors, which can lead to damage and separation of wires.
Innovation Solution
A connector insert with a stabilizer made of dimensionally stable material that surrounds the reception chamber and cable, providing mechanical protection and shielding, which simplifies cable handling and reduces the risk of damage during insertion and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If two-conductor systems are used for data transmission in automobiles, then simplicity and cost-effectiveness are improved, but mechanical stress at plug connections increases the risk of breakdown and wire damage
Solution Approach 1:
The patent applies preliminary action by providing stabilizers that pre-secure the cable core and conductor before the plug connection is made. The stabilizer is inserted into the cable core and conductor in advance, creating a prepared structure that prevents mechanical stress damage during subsequent plug insertion and removal operations.
Solution Approach 2:
The patent implements beforehand cushioning by using stabilizers made of dimensionally stable material that surround and protect the conductor and cable core. These stabilizers absorb and distribute mechanical stresses before they can reach the vulnerable plug connection points, preventing wire damage and separation during operation.
2Ease of operation
If conductors are exposed at plug connections for connection purposes, then ease of connection is improved, but mechanical protection of conductors deteriorates making them susceptible to pulling and kinking
Solution Approach 1:
The stabilizer is inserted into the cable core and conductor before the connection process, preparing a protected structure that allows easy plug insertion while maintaining conductor strength. This preliminary preparation eliminates the need to handle exposed conductors directly during connection.
Solution Approach 2:
The stabilizer acts as an intermediary element between the cable core/conductor and the external environment. It provides a dimensionally stable interface that allows easy connection operations while simultaneously protecting the conductor from mechanical damage, solving both the ease of operation and strength requirements.
3Adaptability or versatility
If cable handling is performed manually during assembly, then flexibility is maintained, but wire damage and separation risks increase
Solution Approach 1:
The stabilizer is pre-inserted into the cable core and conductor, creating a robust structure that enables automated handling without risking wire damage. This preliminary preparation allows transition from manual to automated assembly processes while maintaining wire integrity.
Solution Approach 2:
The stabilizer serves as an intermediary that enables automated manipulation of the cable assembly. By providing a dimensionally stable external structure, it allows automated systems to handle and position the connector without directly manipulating the vulnerable conductors, thus preventing wire damage while enabling automation.
4Strength
If stabilizer material has high dimensional stability for protection, then mechanical strength is improved, but adaptability to different cable configurations may be reduced
Solution Approach 1:
The stabilizer is designed with local quality by providing different structural characteristics at different locations. The dimensionally stable material provides strength where needed for protection, while the overall geometry and insertion method are adapted to accommodate different cable configurations, resolving the contradiction between strength and adaptability.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a connector insert (1) having a housing (2) and a stabiliser (22) composed of dimensionally stable material which is stable in shape. The housing (2) has at least one reception chamber (58) for plug contacts (18) able to be attached to the wires (4) of a cable (6), and an inlet (59) for the plug contacts (18) into the at least one reception chamber (58). The stabiliser (22) is intended to protect mechanically the two individual and exposed wires (4) in a region (8) before the inlet. For this purpose, it consists of a dimensionally stable material and has a fastening location (24) for attachment to the housing (2). In its state mounted on the housing (2), the stabiliser (22) extends away from the inlet (59) and has, spaced apart from the inlet (59), a fastening location (26) for attachment to the cable (6). The stabiliser (22) can be crimped at the fastening locations (24, 26). In addition, the stabiliser (22) can be secured to the fastening location (24) at the housing by form-fitting. The stabiliser (22) can in particular act as shielding. The connector insert (1) serves to transmit data in automobiles by means of a two-conductor or multi-conductor system.