Electrical Connector Size Reduction via Nested Fixing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connectors that hold two wires in parallel within a housing and pull them out to the outside are enlarged in the perpendicular direction due to the arrangement of the fixing portion on one side, which limits their size reduction.
Innovation Solution
The fixing portion is arranged between the two inner conductive members within the housing, with nuts positioned side by side in the extending direction of the wires, allowing the inner conductive members to be fixed by bolts extending in the arrangement direction, eliminating the need for through holes and enabling a narrower configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fixing portion is arranged on one side in a direction perpendicular to both the arrangement direction of the two wires and the extending direction of those two wires, then the inner conductive members can be fixed securely, but the connector size is enlarged in the perpendicular direction
Solution Approach 1:
The fixing portion is relocated from a perpendicular arrangement to an arrangement between the two inner conductive members in the width direction. This dimensional repositioning allows the connector width to be determined by the spacing between inner conductive members rather than by a perpendicular fixing structure, thereby reducing the connector size in the perpendicular direction while maintaining fixing reliability through the bolt-fastening mechanism.
Solution Approach 2:
The fixing portion is nested within the insulation space between the two inner conductive members. By placing the fixing structure inside the existing spatial envelope defined by the conductive members rather than adding it externally in the perpendicular direction, the overall connector dimensions are reduced while still providing secure fastening functionality.
2Length of stationary object
If the fixing portion is arranged between the two inner conductive members, then the connector size is reduced in the perpendicular direction, but the nuts must be arranged side by side in the extending direction of the wires
Solution Approach 1:
The nuts are arranged in the width direction (extending direction of wires) rather than in the perpendicular direction. This repositioning in a different dimension allows the connector width to be minimized while the nut arrangement adapts to the available space along the wire extension, effectively trading one dimensional arrangement for another to achieve overall size reduction.
3Reliability
If the inner conductive members are spaced apart to secure insulation space, then electrical insulation is ensured, but the connector width increases
Solution Approach 1:
The insulation space between the two inner conductive members serves dual functions: it provides electrical insulation between the conductive members and simultaneously houses the fixing portion with nuts and bolts. This multi-functional use of the insulation space eliminates the need for additional perpendicular space for fixing structures, thereby reducing connector width while maintaining insulation reliability.
Data Source
AI summary
A connector includes a housing 10 to be connected to a mating connector, and two conductive unit. Each conductive unit includes a terminal, a wire 43, and an inner conductive member 40 for electrically connecting the terminal and the wire 43. A fixing portion 17 to which the inner conductive members 40 are to be fixed is provided inside the housing 10, one of the inner conductive members 40 is fixed on one side in an arrangement direction of two wires 43 in the housing 10 and the other inner conductive member 40 is fixed on the other side. Each of the two inner conductive members 40 is fixed to the fixing portion 17 by a bolt 22, 23 extending in the arrangement direction.