Connector Housing Exposes Wire Cores for Direct Welding
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Solution Overview
Problem
Connectors connected to wires often require terminal fittings, increasing component count and cost, and are prone to conduction failures due to deformation.
Innovation Solution
A connector design where a first housing with a cavity and opening exposes a core portion of the wire, allowing direct connection with a second stackable housing, eliminating the need for terminal fittings and enabling reliable conduction through exposed core portions that can be welded together.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminal fittings are used to connect wires in connectors, then reliable electrical connection is achieved, but the number of components increases and cost increases
Solution Approach 1:
The invention extracts and eliminates the terminal fittings from the connector system. By removing these intermediate components, the wire cores are exposed directly at the connector tips, enabling direct electrical connection between mated connectors without requiring terminal fittings, thereby reducing component count while maintaining connection reliability
Solution Approach 2:
The invention merges the wire core exposure function directly into the connector housing structure. The housing is designed with openings that expose the wire cores at the connector tips, combining what were previously separate functions (terminal fitting connection and connector housing) into a unified structure, eliminating the need for separate terminal fittings
2Reliability
If terminal fittings are used to connect wires in connectors, then electrical connection is enabled, but conduction failure risk increases due to terminal fitting deformation
Solution Approach 1:
The invention removes the terminal fittings that are prone to deformation and conduction failure. By extracting these vulnerable components from the system, the design eliminates the source of conduction failures related to terminal fitting deformation, while maintaining reliable electrical connection through direct wire core contact
Solution Approach 2:
The invention replaces the durable but deformation-prone terminal fittings with a simpler, more robust direct wire core connection approach. This eliminates the intermediate component that could deform, creating a more reliable conduction path that is less susceptible to failure from component deformation
3Device complexity
If wire core exposed portions are directly connected without terminal fittings, then component count is reduced, but welding accessibility becomes difficult
Solution Approach 1:
The invention segments the connector housing to include dedicated openings and accessible regions that expose the wire cores at the connector tips. This segmentation provides clear access points for welding operations, allowing welding tools to reach the wire cores easily while maintaining the overall integrated connector structure
Solution Approach 2:
The connector housing structure itself provides the welding accessibility feature through its designed openings and exposed core portions. The housing configuration automatically facilitates welding operations by positioning the wire cores in accessible locations, eliminating the need for additional external fixtures or complex assembly procedures
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces the number of components, prevents conduction errors from terminal deformation, and ensures reliable electrical connection by directly connecting corresponding wires without terminal fittings, while allowing for easy welding of core portions.
Implementation Method 1
corresponding core exposed portions are welded to each other
Data Source
AI summary
It is aimed to make connectors accommodating wires conductive to each other without using terminals. Connectors each including wires (2) formed with core exposed portions (2B) by removing parts of coatings (2A) and a connector housing (1) for accommodating the wires (2) while exposing the core exposed portions (2B) in an opening (4) are stacked with the openings (4) facing each other. An operation hole (5) is formed on a side opposite to the opening (4) in the both connector housings (1). Electrodes (9) of a welding machine are inserted through the both operation holes (5) and the core exposed portions (2B) corresponding in a stacking direction are welded to each other. In this way, the wires (2) can be directly connected between the both connectors without using terminals.