Connector Assembly With Resilient Wire Support

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Solution Overview

Problem

Existing electrical connectors either occupy excessive space, lack support for conductors, or require all conductors to be coupled simultaneously, leading to potential damage from over-torquing and incorrect coupling.

Innovation Solution

A connector assembly comprising a non-conductive block assembly with aligned passages and a resilient wire support, allowing individual conductors to be selectively coupled while resisting damage through a secure and space-efficient design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If a single conductor with a lug is used to connect to a socket, then the connector occupies more space, but the conductor is not supported and may be inserted into the wrong socket

Engineering Contradiction:

Improveconnector space occupationVSAvoidconductor coupling accuracy

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The connector body is designed with an asymmetrical shape that does not match any socket except the intended one. This prevents accidental insertion into wrong sockets while maintaining a compact single-connector design rather than using multiple individual sockets

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The single connector body serves multiple functions: it provides mechanical support for the conductor, ensures correct socket matching through asymmetrical design, and enables electrical connection. This multi-functionality eliminates the need for separate support structures and reduces overall space occupation

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of operation

If a multiple pin connector with a body is used, then all conductors must be coupled to the socket at the same time, but selective coupling of individual conductors is required

Engineering Contradiction:

Improveselective conductor couplingVSAvoidconnector structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The connector system is divided into separable components: the connector body with multiple sockets and individual conductors with lugs. This allows each conductor to be independently coupled to its corresponding socket, enabling selective coupling while maintaining a relatively simple overall structure

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connector design allows for dynamic assembly where conductors can be coupled to sockets in any sequence and at different times. The asymmetrical body shape provides guidance for proper orientation, but the individual conductor-socket pairs can be assembled independently, offering operational flexibility

Inventive Principle:

Principle #15Dynamics

3Reliability

If a harness connector with threaded posts is used, then individual conductors can be selectively coupled, but the connector does not support the conductor and is vulnerable to over-torquing damage

Engineering Contradiction:

Improveconductor supportVSAvoidover-torquing damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The threaded nut-and-post mechanical coupling system is replaced with a push-fit connector system. The asymmetrical connector body with corresponding sockets accepts lugs through a simple insertion motion without requiring threading or torquing, thereby supporting the conductor securely while eliminating the risk of over-torquing damage

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The asymmetrical shape of the connector body provides built-in alignment and positioning features that guide the lug into the correct socket during insertion. This self-aligning mechanism eliminates the need for additional alignment hardware or complex coupling mechanisms, providing both conductor support and protection against misuse

Inventive Principle:

Principle #25Self-service

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 solution provides a compact, secure, and damage-resistant electrical connector that supports individual conductors, enabling selective coupling and efficient use of space, while being compatible with existing hardware.

Implementation Method 1

a resilient wire support... Each resilient wire support passage aligned with one block assembly passage

Methodology Applied

Scientific EffectResilience: Elasticity

Data Source

PatentEP2951890B1Connector assembly

Publication Date: 2017.06.14 LABINAL LLC

Figure 1~2
Figure 3~3B
Figure 4

AI summary

A connector assembly (10) includes a non-conductive block assembly (12) defining a plurality of passages (20) and a resilient wire support (14) defining a plurality of passages (66). The resilient wire support (14) is coupled to the block assembly (12) with each resilient wire support passage (66) aligned with one block assembly passage (20). A conductor unit includes a plurality of conductor assemblies (80). Each conductor assembly (80) includes a first socket (90) and a second socket (94), and each such conductor assembly (80) is disposed partially in a block assembly passage (20).