Electric Connector Wire Holder Centralizing Ribs
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Solution Overview
Problem
Existing electric connectors face challenges in securely aligning and terminating cables with wires of different sizes due to the limited size compatibility of wire support passages, leading to misalignment and improper contact with insulation piercing contacts.
Innovation Solution
The electric connector design includes a wire holder with a wire support extension featuring aligned wire receiving passages and centralizing ribs, which can accommodate wires of varying diameters, ensuring proper alignment and secure engagement with contact insert slots, even when the wires are of different sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If wire support passages are dimensioned to fit wires of a particular size, then alignment precision for that size is improved, but adaptability to wires of different sizes deteriorates
Solution Approach 1:
The wire support passages incorporate centralizing ribs that create localized alignment features within the passages. These ribs provide specific geometric constraints at critical locations to ensure precise alignment of wires with insulation piercing contacts, while the overall passage geometry remains adaptable to different wire sizes through the conically tapered inner mating portions.
Solution Approach 2:
The wire support passages utilize conically tapered inner mating portions that can accommodate wires of varying diameters. The conical geometry allows the passage dimensions to effectively change along its length, providing a transition zone that adapts to different wire sizes while maintaining proper alignment through the centralizing ribs.
2Ease of operation
If wires are independently engaged into the plug housing, then ease of operation is improved, but manufacturing precision deteriorates due to misalignment and unsecured positioning
Solution Approach 1:
The wire holder serves as an intermediary component between the wires and the plug housing. It provides a structured platform with wire support passages that guide and align wires during insertion, ensuring precise positioning relative to insulation piercing contacts while simplifying the assembly process through the modular wire holder design.
Solution Approach 2:
The wire holder pre-arranges wires in the correct configuration and alignment before they are inserted into the plug housing. The wire support passages are designed to receive and position wires in advance, ensuring they are properly aligned with the insulation piercing contacts before the final termination step occurs.
Data Source
AI summary
An electric connector is provided to ensure reliable termination of cable wires having different sizes. The electric connector can include a housing, a plurality of contacts, and a wire holder. The wire holder includes a wire support extension configured to be at least partially inserted into the housing. The wire support extension defines a plurality of wire receiving passages configured to arrange a plurality of first wires thereon and align the first wires with contact insert slots of the housing, respectively, when the wire support extension is inserted to the housing. The wire holder further includes a plurality of wire support ribs configured to centralize second wires smaller than the first wires.