Dovetail Connector Assembly for Modular Fit and Deformation Control
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Solution Overview
Problem
Conventional connectors require multiple molds for different car models, leading to complex assembly processes and potential deformations due to stress, which affect electrical properties and connection reliability.
Innovation Solution
A dovetail structure with a pin module and slot module, featuring guide blocks and slots with specific edge distances and concave structures, allowing for modular assembly, easy alignment, secure connection, and deformation accommodation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional connectors are used for different car models, then different molds are required to meet different requirements, but this increases device complexity and manufacturing cost
Solution Approach 1:
The connector body is designed with a universal structure that can accommodate different connector quantities (two, three, four, or five connectors) through a standardized modular arrangement. The casing includes a universal mounting structure with positioning protrusions and recesses that work across all configurations, eliminating the need for different molds for each car model requirement
2Adaptability or versatility
If modular combining methods are used to overcome connector quantity requirements, then connector versatility is improved, but assembly time and effort increase significantly
Solution Approach 1:
The connector assembly is divided into modular units (first connector, second connector, third connector, fourth connector) that can be independently manufactured and then quickly assembled. Each connector module has standardized interfaces with positioning protrusions and recesses that enable rapid assembly without complex alignment procedures, reducing assembly time while maintaining configuration flexibility
Solution Approach 2:
Multiple connector modules are combined within a single casing structure that provides unified support and positioning. The casing integrates mounting structures for all connector types, allowing them to be assembled together as a coordinated unit rather than individually, thereby reducing total assembly time while preserving the ability to configure different numbers of connectors
3Adaptability or versatility
If connectors are assembled modularly with varying quantities, then adaptability is improved, but deformations occur due to stresses and tensions affecting connection reliability
Solution Approach 1:
The casing is designed with location-specific mounting structures tailored to each connector position. Each connector mounting area has customized positioning protrusions, recesses, and reinforcement features that provide optimal local support and stress distribution. This localized structural optimization ensures reliable connections for each connector regardless of the total quantity assembled, preventing deformations while maintaining adaptability
4Ease of manufacture
If conventional assembly methods are used, then manufacturing simplicity is maintained, but alignment precision and fit quality deteriorate
Solution Approach 1:
Positioning protrusions and recesses are pre-formed during the molding process of the connector modules and casing. These positioning features are built into the structure beforehand, eliminating the need for complex alignment procedures during assembly. The pre-integrated positioning structures guide accurate alignment automatically, ensuring high manufacturing precision while keeping the assembly process simple and straightforward
Data Source
AI summary
The present invention provides a dovetail structure of a connector that can be disposed on a first joint surface and a second joint surface of a casing. The dovetail structure includes a pin module and a slot module. An interference structure formed by the pin module and the slot module enables the two connectors with a dovetail structure to be assembled easily to achieve a stable combination.