Connector Assembly With Sliding Sheath for Core Wire Insertion
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Solution Overview
Problem
The challenge in manufacturing connectors is the difficulty in inserting a core wire into a female terminal due to potential contact between the front end of the core wire and the rear end of the female terminal, making it difficult to complete the assembly process.
Innovation Solution
The connector design includes a sheath portion in the insulation coating of the wire, which is slidable and separates from the body portion, allowing the core wire to be protected and easily inserted into the insertion tube portion of the terminal, guided by contact portions and a guiding portion, facilitating alignment and insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the core wire is inserted directly into the female terminal without insulation protection, then the insertion process becomes simple, but the front end of the core wire contacts the rear end of the female terminal making insertion difficult
Solution Approach 1:
The insulation coating is divided into two separate portions: a sheath portion and a body portion. The sheath portion remains on the core wire to protect its front end, while the body portion is separated and disposed behind it. This segmentation allows the core wire to be inserted easily without the insulation coating interfering with the terminal's rear end, resolving the contradiction between insertion ease and insulation protection.
Solution Approach 2:
The body portion of the insulation coating is extracted or removed from the core wire at a specific location, creating a gap between the front end protection (sheath portion) and the rear end of the terminal. This extraction allows the core wire to pass through the terminal without contact obstruction, while maintaining protective insulation where needed.
2Reliability
If the insulation coating is continuous and covers the entire core wire, then the core wire is fully protected, but it interferes with the insertion into the terminal
Solution Approach 1:
The continuous insulation coating is segmented into a sheath portion and a body portion. The sheath portion remains intact on the core wire to provide protection, while the body portion is separated to eliminate interference with terminal insertion. This segmentation maintains reliability through continued protection while simplifying the assembly process.
Solution Approach 2:
The insulation coating is pre-separated into distinct portions before the assembly process. The sheath portion is positioned on the core wire in advance to protect the front end, while the body portion is prepared for separation. This preliminary action ensures that during assembly, the core wire can be inserted without obstruction while maintaining protective coverage where needed.
Data Source
AI summary
A connector 10 comprises an electric wire 40 having a core wire 41 and an insulating coating 42 covering the outer periphery of the core wire 41, a terminal 50 connected to the core wire 41, a connector housing 20 having a terminal storage part 21 in which the terminal 50 is stored, and a rear holder 30 attached to the rear end portion of the connector housing 20. The rear holder 30 has an electric wire insertion hole 33 in which the electric wire 40 is inserted, the terminal 50 includes an insertion cylindrical part 55 in which the core wire 41 is inserted from the rear and a contact part 56 that is disposed at the rear end portion of the insertion cylindrical part 55 and faces the electric wire insertion hole 33, the insulating coating 42 of the electric wire40 has a sheath portion 43 and a body portion 44 as separate portions, and the sheath portion 43 is disposed in front of the body portion 44 and is slidable with respect to the core wire 41.