Connector Insertion Detection Translational Flap Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connectors with moulded hinges in the automotive sector face challenges in resisting mechanical and thermal constraints, particularly when using filled plastic materials, which results in low mechanical resistance to bending.
Innovation Solution
A connector design featuring translatably mobile pre-assembled elements with no hinges or deformable portions, where a moulded body and flap form a single hinged part, using guiding slides and longitudinal stops for secure locking and positioning of electrical contacts, and complementary features to prevent improper insertion or removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a moulded hinge is used in the connector flap, then the connector can be produced as a single integrated part, but the mechanical resistance to bending is too low especially when using filled plastic materials
Solution Approach 1:
The connector is divided into two separate elements: a body and a flap that forms a mobile element. The flap is produced as a separate injection-moulded piece that can be assembled to the body, eliminating the need for a weak moulded hinge while maintaining integrated production benefits.
Solution Approach 2:
The hinge function is extracted from the moulded body structure and implemented through a separate mobile flap element with its own reinforcement. This removes the constraint of relying on the body material's bending resistance for hinge functionality.
2Manufacturing precision
If a foldable flap with inner protrusions is used to prevent tilting, then contact positioning is improved, but the flap structure becomes more complex and harder to produce
Solution Approach 1:
The side flanks of the flap act as guiding elements that cooperate with the body to provide precise positioning and guiding of the contact during insertion, replacing the need for complex inner protrusions while maintaining positioning accuracy.
Data Source
AI summary
An electrical connector includes a molded body having at least one recess for receiving an electrical contact crimped onto a power supply wire. The body includes a flap that is mobile between a position allowing the insertion of a contact into the recess, and a locked position in which the flap locks the contact in the recess. The flap is translatably mobile relative to the body and forms a single hinged part with the latter. A system also includes a bulb provided with a connection socket and the connector.