Connector Shroud Rounded Transitions to Minimize Warping
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Solution Overview
Problem
Lightweight connector assemblies in automotive vehicles are less robust, requiring additional care for connections due to reduced material and weight considerations, which can lead to issues with warping and undesirable contact during assembly.
Innovation Solution
A connector design featuring a shroud with rounded transitions between sidewalls, having a radius of curvature greater than 90 degrees, and a smaller transition dimension than the sidewall dimension, which reduces the likelihood of warping and undesirable contact with terminals, made from glass-filled nylon material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If lightweight materials and reduced material usage are employed to improve fuel economy and reduce weight, then weight is reduced, but robustness and structural strength deteriorate
Solution Approach 1:
The shroud features rounded transitions at corners and edges instead of sharp angles, with radii of curvature between 0.03 inches to 0.06 inches. This curvature distributes stress more evenly throughout the structure, preventing stress concentration at sharp corners while maintaining lightweight construction. The rounded geometry provides structural reinforcement without adding significant weight or material usage.
2Ease of manufacture
If sharp transitions and right-angled corners are used in shroud design, then manufacturing is simpler, but warping and undesirable contact during assembly increase
Solution Approach 1:
The shroud incorporates rounded transitions with controlled radii of curvature (0.03-0.06 inches) at all corners and edges. This curvature eliminates stress concentration points that cause warping during injection molding, while the standardized rounding process maintains manufacturing efficiency. The rounded geometry naturally guides alignment during assembly, preventing undesirable contact between mating connectors.
3Manufacturing precision
If transition dimensions are reduced to minimize warping, then warping is reduced, but the protective coverage and structural integrity may be compromised
Solution Approach 1:
The shroud design applies different dimensional characteristics to different regions: the transition zones have reduced dimensions (0.03-0.06 inch radii) to minimize warping, while the main sidewalls and terminal coverage areas maintain full protective dimensions. This localized differentiation optimizes both warping control and terminal protection, ensuring structural integrity where needed while minimizing distortion in transition zones.
Data Source
Figure 1~2
Figure 3~4
AI summary
An illustrative example embodiment of a connector includes a terminal configured to establish an electrically conductive connection with another component and a shroud surrounding the terminal. The shroud includes a first sidewall and a second sidewall that is transverse to the first sidewall. The first sidewall and the second sidewall have a sidewall dimension in a direction parallel to a longitudinal axis of the terminal. The shroud includes a first transition between the first sidewall and the second sidewall in the form of a hollow cylindrical sector having a first angular measurement of more than 90 degrees. The transition has a transition dimension that is less than the sidewall dimension.