Connector Shield Wire Routing and Housing Segmentation
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Solution Overview
Problem
Conventional connectors face difficulties in accommodating thick shield electric wires within L-shaped shell conductors, leading to reduced workability due to rattles between the shell conductor and housing cover, making assembly challenging.
Innovation Solution
A method involving a conductive housing with a rear wall and annular wall, where the shield electric wire is passed through and bent, a shield terminal is connected, and an L-shaped terminal is accommodated within the housing, with an inner housing and outer housing configuration that allows for secure fastening without rattles, using a bolt and wire seal for waterproofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a thick shield electric wire is accommodated within an L-shaped shell conductor by bending it, then the wire can be routed through the housing, but it becomes difficult to bend the wire into the required shape and rattles occur between the shell conductor and housing cover
Solution Approach 1:
The housing is divided into multiple parts: a housing main body and a housing cover. The shell conductor is selectively assembled within the housing cover first, then the entire housing cover assembly is attached to the housing main body. This segmentation allows the thick shield electric wire to be accommodated within the shell conductor without requiring precise fit between the shell conductor and housing cover, eliminating rattles while maintaining ease of manufacture.
2Reliability
If a lance or lock projection is used as a lock to fix the shell conductor, then the shell conductor can be secured, but the assembly process becomes complex and workability is reduced
Solution Approach 1:
The locking function is extracted from the shell conductor-housing cover interface and relocated to the housing cover-housing main body interface. The lock projection is formed on the housing cover to engage with the housing main body, while the shell conductor is simply received within the housing cover without requiring additional locking mechanisms. This reduces device complexity while maintaining reliability of securing the shell conductor in place.
3Ease of manufacture
If the shield electric wire is bent to fit the L-shaped shell conductor, then the wire can be accommodated, but the thick wire becomes difficult to bend and assembly workability is reduced
Solution Approach 1:
The shell conductor is designed with an L-shape configuration that provides dynamic routing capability for the shield electric wire. The wire can be routed through the tube wall opening and along the L-shaped path without requiring sharp bending. The housing cover is then attached to secure the wire in this routed position, making the accommodation process easy while maintaining ease of operation with thick wires.
Data Source
AI summary
In order to avoid cost for accommodating a shield wire in a housing while bending, and smoothly and readily accommodate within the housing while the shield electric wire is insulated, a conductive housing 1 including a rear wall 4 continuing to an annular wall 3, and a tube wall 5 continuing to down the rear wall 4, a method comprising the steps of: passing through a shield electric wire 2 from a lower opening 5a of the tube wall of the conductive housing to a front opening 3a of the annular wall while bending the shield electric wire; putting a shield terminal 9 movably around the shield electric wire from top of the shield electric wire; exposing a core wire 2b and a braid 2a of the shield electric wire by stripping a tip thereof; connecting an L-shaped terminal 11 to the core wire; mounting an L-shaped insulation inner housing 12 outside the L-shaped terminal; connecting the shield terminal to the braid; and accommodating a vertical part 14 of the inner housing within the conductive housing by pulling in the shield electric wire in an direction contrary to that of the shield electric wire having being passed through, so as to project a horizontal part 13 of the inner housing from the front opening.