Connector Sealing with Lever-Actuated Positioning Pins
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Solution Overview
Problem
Existing connectors face limitations in sealing effectiveness due to reliance on a single resilient reaction force for wire insulation coating sealing, which restricts improved sealing and operability.
Innovation Solution
A connector design featuring a one-piece resilient plug with positioning pins and narrowed positioning holes that enhance sealing by squeezing inner lips against wire insulation coatings, combined with a force multiplying mechanism and a wire cover for improved alignment and sealing uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a one-piece rubber plug with seal lips is used to seal wires, then the sealing structure is simple, but the sealing force is insufficient and limited
Solution Approach 1:
The connector is divided into fixed-side connectors and lever-side connectors that can be assembled separately. The lever-side connector includes a lever mechanism that applies additional sealing force to the rubber plug, separating the sealing function into multiple components working together.
Solution Approach 2:
The rubber plug is pre-installed in the lever-side connector housing with positioning holes and narrowed portions formed beforehand. When the lever is actuated, it applies force through the positioning pins to the narrowed portions, which then exert concentrated sealing force on the wire insulation coatings before final connection is made.
2Reliability
If positioning pins are inserted into positioning holes with narrowed portions, then sealing force is enhanced, but the manufacturing precision requirement increases
Solution Approach 1:
The positioning holes are designed with narrowed portions that create a mechanical interference fit with the positioning pins. This parameter change in the hole geometry (from uniform diameter to narrowed section) allows the positioning pins to be inserted with moderate force while maintaining precise alignment, as the narrowed portions act as locators that guide the pins into correct positions.
Solution Approach 2:
The narrowed portions in the positioning holes automatically align the positioning pins during insertion. The geometry of the narrowed portions and pins is designed so that the pins self-align and insert into the correct positions without requiring external alignment tools or complex positioning mechanisms, reducing the overall manufacturing precision requirements.
3Reliability
If multiple positioning holes are arranged at diagonally symmetric positions, then sealing uniformity is improved, but the device complexity increases
Solution Approach 1:
While the overall arrangement is symmetric, the positioning holes are strategically placed at diagonally symmetric positions relative to the wire insertion holes. This asymmetric placement pattern within a symmetric framework allows multiple positioning pins to apply force at different locations, creating uniform radial compression on the rubber plug and wires, while maintaining a relatively simple hole pattern that is easy to manufacture.
4Force
If a lever mechanism with slider is used for force multiplying, then connection force is enhanced, but the device complexity increases
Solution Approach 1:
The lever mechanism transforms a small static force applied to the lever handle into a large dynamic force at the connection point. The slider moves along the lever arm, converting rotational motion into linear motion that actuates the positioning pins. This dynamic mechanism provides force multiplication while maintaining operational simplicity through the lever's mechanical advantage.
Solution Approach 2:
The slider acts as an intermediary component between the lever handle and the positioning pins. It translates the lever's rotational movement into the linear motion required to push the positioning pins into the narrowed portions of the positioning holes, providing mechanical advantage and force multiplication without requiring a complex direct connection mechanism.
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
The design achieves enhanced sealing forces and improved operability by uniformly distributing sealing forces around wire insertion holes and utilizing a force multiplying mechanism to ensure secure connections.
Implementation Method 1
a material around the positioning hole is strongly pushed outward at the narrowed portion formed in the positioning hole
Implementation Method 2
positioning pins to squeeze the inner lips tightly against the wire to enhance sealing
Data Source
AI summary
A connector (L1) has a one-piece rubber plug (39) with wire insertion holes (45) to collectively seal wires (W) drawn out from the rear end surface of an inner housing (22) by inserting the wires into the corresponding wire insertion holes (45). The connector (L1) has wall surfaces (23, 41) for sandwiching the one-piece rubber plug (39) from front and rear in an inserting direction of the wires (W). Positioning pins (48) project substantially parallel with axial directions of the wire insertion holes (45) from the wall surface (41) on the side of the inner housing (22) toward the one-piece rubber plug (39) and to be inserted and press-fit into positioning holes 51 arranged near the wire insertion holes (45). Narrowed portions (51A) having a small hole diameter are formed at axial intermediate positions of the positioning holes (51).