Connector Unit with Movable Spacer for Terminal Retention
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Solution Overview
Problem
Conventional connectors with spacers may fit improperly due to insufficient locking force, leading to terminals falling out during wiring harness routing, especially when the spacer is in a middle insertion condition and the projection length is smaller than the clearance or when pushed obliquely.
Innovation Solution
The connector unit features a first and second connector with specific concave and convex shapes and a movable spacer that projects from multiple positions in a temporary locking position, allowing easy detection of the middle insertion condition and ensuring the terminal remains locked in the regular position, preventing it from falling out.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spacer is added to prevent terminal from falling out, then terminal retention is improved, but device complexity increases
Solution Approach 1:
The spacer is inserted into a dedicated receiving chamber within the connector housing, nesting the spacer inside the existing connector structure. This allows the spacer to provide terminal retention functionality without adding external complexity, as the spacer is housed within the existing connector geometry rather than being an external addition.
Solution Approach 2:
The spacer acts as an intermediary component between the terminal and the connector housing. It provides a mechanical stop that prevents the terminal from falling out while allowing the terminal to be properly positioned and retained during assembly. The spacer mediates the interaction between the terminal and housing, ensuring reliable retention without requiring direct complex engagement mechanisms.
2Ease of operation
If clearance is provided for smooth fitting, then ease of operation is improved, but detection precision of spacer position deteriorates
Solution Approach 1:
The detection mechanism transitions from linear position detection to angular/rotational detection. The fitting convex and concave features are designed with specific rotational engagement characteristics that allow the detection portion to sense the spacer's insertion state through rotational movement rather than linear displacement. This dimensional change enables precise detection while maintaining fitting clearance.
Solution Approach 2:
The detection mechanism utilizes visual feedback through color or positional indication. When the spacer is in the middle insertion condition, the detection portion rotates to a specific angular position that can be visually detected, providing clear feedback on the spacer's state. This visual indication system allows operators to easily detect the spacer position without requiring precise linear measurement.
3Device complexity
If projection length of spacer is reduced, then device complexity is reduced, but reliability of terminal locking deteriorates
Solution Approach 1:
The spacer features asymmetric projection lengths at different locations. The detection portion has a shorter projection optimized for detection functionality, while the locking portion has a longer projection optimized for terminal retention. This asymmetric design allows each portion to be optimized for its specific function without compromising overall reliability, as the locking force is provided by the longer projection while the shorter projection handles detection.
Solution Approach 2:
The spacer is segmented into functionally distinct portions: a detection portion with shorter projection for position sensing and a locking portion with longer projection for terminal retention. This segmentation allows each portion to be optimized independently for its specific function, maintaining reliable terminal locking while keeping the overall spacer structure simple and functional.
Data Source
AI summary
A first connector housing of a first connector includes a fitting concave having an inner wall portion extended in a fitting direction X and formed in substantially a circular shape, and the inner wall portion has a first step portion extended perpendicular to the fitting direction X and projected inward. A second connector housing of a second connector includes a fitting convex having an outer wall portion extended in the fitting direction X and formed in substantially a columnar shape, and the outer wall portion has a second step portion indented inward corresponding to the first step portion. A spacer is projected from at least two positions of a part of the outer wall portion and the second step portion in a temporary locking position, and is sunken in the outer wall portion or arranged in the same plane as the outer wall portion in a regular locking position.