Connector Shielding Walls for Erroneous Insertion and Contaminant Blocking

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Solution Overview

Problem

Conventional connectors with fewer terminal accommodating chambers than maximum capacity face challenges in preventing contaminant diffusion and avoiding damage to mating terminals when inserted erroneously, as existing countermeasures are labor-intensive and costly, and ineffective in blocking contaminants through engagement gaps.

Innovation Solution

The connector design includes a first shielding wall in empty terminal accommodating chambers to allow erroneous terminal insertion without damage and a second shielding wall to block contaminants, preventing entry through wire withdrawal openings and engagement gaps without additional components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If hole caps or dummy terminals are fitted into unused terminal accommodating chambers to prevent contaminant entry, then contaminant diffusion is prevented, but labor cost and component cost increase

Engineering Contradiction:

Improvecontaminant preventionVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The terminal accommodating chamber is divided into two functional zones by a shielding wall: a first space that allows erroneous terminal insertion and a second space that blocks contaminant entry through the wire withdrawal opening. This segmentation eliminates the need for additional hole caps or dummy terminals while maintaining contaminant prevention.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connector housing itself provides the protective function through the integrated shielding wall structure, eliminating the need for separate protective components. The shielding wall serves multiple functions: blocking contaminants, allowing erroneous insertion, and maintaining structural integrity, thereby reducing component count and manufacturing complexity.

Inventive Principle:

Principle #25Self-service

2Reliability

If a shielding wall is provided to block contaminant entry through the wire withdrawal opening, then contaminant diffusion is prevented, but erroneous terminal insertion may cause damage

Engineering Contradiction:

Improvecontaminant preventionVSAvoidterminal damage risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first space in front of the shielding wall acts as a buffer zone that absorbs the impact of erroneously inserted terminals before they reach the shielding wall. This prevents damage to both the terminal and the shielding wall structure while maintaining the contaminant-blocking function.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of manufacture

If the connector housing structure is simplified to reduce manufacturing cost, then ease of manufacture is improved, but contaminant entry through engagement gaps increases

Engineering Contradiction:

Improvestructural simplicityVSAvoidcontaminant sealing

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The shielding wall is positioned specifically at the wire withdrawal opening where contaminant entry is most critical. This localized protective measure provides effective contaminant blocking without requiring complex sealing structures throughout the entire connector housing, maintaining both simplicity and reliability.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS9112297B2Connector having terminal accommodating chambers

Publication Date: 2015.08.18 YAZAKI CORP

AI summary

A female connector housing is provided with a plurality of terminal accommodating chambers. Each of the terminal accommodating chambers is provided, on its front face, with a terminal insertion opening through which a male terminal is to be inserted. Each of the terminal accommodating chambers is provided, on its rear face, with a wire withdrawal opening. In the terminal accommodating chamber which is intended to accommodate no terminal, there are provided a first shielding wall which surrounds an erroneous-insertion allowable space allowing the male terminal to be inserted erroneously and shields the interior of the erroneous-insertion allowable space and a second shielding wall for shielding the wire withdrawal opening.