Die-Cast Elbow Cable Connector Structure for High-Strength Sealing
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Solution Overview
Problem
Existing elbow cable connectors lack sufficient strength for use in vehicle applications or industrial fields, where they are subjected to higher stress and durability requirements.
Innovation Solution
The proposed elbow cable connector features a die-cast head with a fixing hole and receiving groove, an outer conductor with a rear flange that presses against the head, and a rear cover that seals the receiving groove, providing enhanced structural integrity and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If stamping and forming method is used to manufacture shell parts, then manufacturing cost is reduced and size is reduced, but strength is insufficient
Solution Approach 1:
The patent employs a composite structure combining metal components (head, rear cover, outer conductor) with insulator materials. The metal parts provide structural strength while the insulator provides electrical insulation. This composite approach resolves the contradiction by maintaining strength through metal components while allowing cost-effective manufacturing of specific parts through stamping and forming methods.
Solution Approach 2:
The connector is divided into multiple components: head, rear cover, outer conductor, insulator, and sealing ring. Each component can be manufactured using the most appropriate method for its functional requirements. The head and rear cover can be stamped and formed for cost efficiency, while maintaining overall structural strength through the integrated assembly of multiple parts.
2Volume of moving object
If stamping and forming method is used to manufacture shell parts, then size is reduced, but strength is insufficient
Solution Approach 1:
The combination of metal and insulator materials creates a compact yet strong structure. The metal components provide strength-to-volume efficiency, while the insulator material allows for optimized spatial arrangement. This composite approach enables reduced overall size while maintaining necessary mechanical strength for vehicle and industrial applications.
Solution Approach 2:
The patent implements a nested structure where the insulator is received within the head, the outer conductor surrounds the insulator, and the rear cover encloses the rear portion. This nesting arrangement minimizes overall connector size while each layer contributes to the structural strength, resolving the contradiction between compact size and sufficient strength.
3Strength
If die casting is used for head, then strength is improved, but manufacturing complexity increases
Solution Approach 1:
The connector is segmented into components with different manufacturing methods. The head uses die casting for high strength where needed, while other parts like the rear cover and shell parts can use simpler stamping and forming methods. This segmentation reduces overall manufacturing complexity while maintaining strength in critical areas.
Solution Approach 2:
The die-cast head integrates multiple functions: structural support, electrical connection interface, and mounting features. By combining these functions into a single die-cast component, the patent reduces the number of separate parts needed, thereby reducing overall manufacturing complexity despite the higher complexity of the die casting process itself.
Data Source
AI summary
An elbow cable connector includes: a cable assembly comprising a head, an outer conductor extending forwards, an insulator received in the outer conductor, an inner conductor received in the insulator, a cable mechanically connected with the inner conductor and extending downwards, and a rear cover; and an outer shell surrounding the outer conductor, the head, and an upper end of the cable; wherein the head is of a die casting and has a fixing hole running forwards and a receiving groove opening rearwards and downwards, the outer conductor has a rear flange on a rear end thereof, the outer conductor goes across the fixing hole and the rear flange presses against a front face of the receiving groove, a rear part of the insulator and the upper end of the cable are received in the receiving groove, and the rear cover presses forward and seal the receiving groove.