Multi-Stage Connector Sub-Housing Retention Design
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Solution Overview
Problem
Existing connectors can only stack terminal fittings up to two stages due to limitations in retaining mechanisms, leading to increased component count when trying to stack more stages without proper retention for uppermost stage terminals.
Innovation Solution
A connector design with sub-housings that include an upper sub-housing for retaining middle sub-housing terminals and a middle sub-housing for retaining both upper and lower sub-housing terminals, using retainers and retention receiving portions aligned in the front-rear direction to lock terminals across multiple stages without increasing the connector's size, along with error connection preventing portions to ensure correct stacking order.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If retainers are added to retain terminals in uppermost stage sub-housings, then terminal retention is improved, but the number of components increases
Solution Approach 1:
The retainer on the middle sub-housing serves multiple functions: it retains terminals in the upper sub-housing and also retains terminals in the lower sub-housing. This multi-functional design eliminates the need for separate retainers for each stage, reducing component count while maintaining reliable terminal retention across all stacked sub-housings
Solution Approach 2:
The patent combines the retention function for both upper and lower sub-housing terminals into a single retainer structure on the middle sub-housing. By merging these retention functions into one component rather than using separate retainers for each function, the design reduces the total number of components while ensuring proper terminal retention
2Quantity of substance
If sub-housings are stacked in three or more stages, then terminal capacity is improved, but terminal retention reliability deteriorates
Solution Approach 1:
The connector is segmented into multiple sub-housings (upper, middle, lower) that can be stacked in three or more stages. Each sub-housing contains terminals and works with retainers on adjacent sub-housings to provide retention. This segmentation allows increased terminal capacity while maintaining reliable retention through the distributed retainer arrangement
Solution Approach 2:
The patent implements a nested structure where sub-housings are stacked vertically in multiple stages, with each sub-housing containing terminals and being retained by retainers on adjacent sub-housings. The middle sub-housing's retainer nests within the structure to retain both upper and lower terminals, creating a compact multi-stage configuration that maintains reliability
3Volume of moving object
If retainers are positioned at the same front-rear location, then connector size is reduced, but alignment precision requirements increase
Solution Approach 1:
The retainer and retention receiving portion are designed with asymmetric geometries that provide built-in alignment guidance. The retainer has a specific shape with engagement surfaces that must match corresponding features on the retention receiving portion, creating a self-aligning mechanism that reduces the need for high-precision manual alignment during assembly while maintaining compact dimensions
Data Source
AI summary
A connector (10) includes a stacked housing (11) configured by vertically stacking sub-housings (S) capable of accommodating terminals (T) in three or more stages. The stacked housing (11) includes, as the sub-housings (S), an upper sub-housing (S1) disposed in an uppermost stage, a middle sub-housing (S2) disposed to face the upper sub-housing (S1) and a lower sub-housing (S3) disposed in a lowermost stage. The upper sub-housing (S1) includes a retainer (35) for retaining the terminals (T) accommodated inside the middle sub-housing (S2) and the middle sub-housing (S2) includes at least two retainers (35) for retaining the terminals (T) accommodated in the upper sub-housing (S1) and the terminals (T) accommodated in the lower sub-housing (S3).