Connector Insulating Wall Alignment for Size-Constrained Insulation
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Solution Overview
Problem
Existing connectors face challenges in maintaining a small size while ensuring adequate insulation distance between adjacent conductors, as the inclusion of insulating walls to achieve this often leads to increased connector size.
Innovation Solution
A connector design featuring an insulating housing, a conductor unit with conductors and an integrally molded insulating holding body, and a sealing member, where the holding body includes fitting parts, covering parts, and insulating walls that extend along the gaps between conductors to divide terminal parts, allowing for effective insulation without increasing the connector's size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating walls are provided to secure insulation distance between adjacent conductors, then insulation distance is improved, but connector size increases
Solution Approach 1:
The insulating wall is positioned on the extension line of the gap between covering parts, utilizing the longitudinal dimension along the conductor rather than expanding in the transverse direction. This allows the insulating wall to divide adjacent terminal parts effectively while maintaining a compact connector cross-section, thus securing insulation distance without increasing connector size.
Solution Approach 2:
The insulating wall is provided only where absolutely necessary - on the extension line of the gap between covering parts - rather than providing comprehensive insulation throughout. This localized approach ensures insulation distance is secured at critical points while minimizing the overall volume of insulating material and connector size.
2Reliability
If insulating walls are provided to divide terminal parts of adjacent conductors, then insulation reliability is improved, but the number of parts and complexity increases
Solution Approach 1:
The insulating wall is integrally formed with the holding body as a single molded part, eliminating the need for separate insulating components. This merging of the insulating wall into the holding body structure ensures insulation reliability while reducing the number of parts and simplifying assembly, directly addressing the contradiction between reliability and complexity.
Data Source
AI summary
A connector includes an insulating housing, a conductor unit having a plurality of conductors arranged in a row and an insulating holding body integrally molded with the conductors, and a sealing member that seals between the conductor unit and the housing. Each of the conductors includes a plate-shaped body and terminal parts provided at both ends of the body, respectively. The holding body includes a fitting part fitted to the housing, a plurality of covering parts each extending from the fitting part along the body and individually surrounding the body, and insulating walls each dividing two adjacent terminal parts. Each of the insulating walls has a main wall part and the main wall part extends on an extension line of a gap between two adjacent covering parts and divides two adjacent terminal parts.