Entrapping Structure for Electrical Connector Wire Intrusion

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Solution Overview

Problem

The dimensional tolerance between the connector housing and the case in electrical connectors leads to gaps that allow wires to intrude and potentially reach hazardous high-voltage areas on circuit boards, limiting the layout and positioning of electrical connectors.

Innovation Solution

An electrical apparatus with an electrical connector and a case featuring an entrapping structure with a dead end that guides and prevents wires from intruding into the circuit board, using a combination of flanges and dead ends to redirect and trap wires, ensuring they do not reach the hazardous area.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If dimensional tolerance is allowed between connector housing and case, then manufacturing ease is improved, but wire intrusion risk increases

Engineering Contradiction:

Improvedimensional toleranceVSAvoidwire intrusion

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The gap between connector housing and case is segmented into multiple regions by protrusions and recesses. The protrusion from the connector housing divides the gap into a first gap and second gap, while the recess in the case further segments it. This segmentation prevents wires from continuously passing through the entire gap, as wires intruding into dead end regions cannot reach the circuit board.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The protrusion and recess structures act as intermediary elements between the connector housing and case. These intermediaries create dead end regions that intercept wires before they can reach the hazardous circuit board area, thus mediating the potential harm from wire intrusion while maintaining manufacturing tolerance.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If layout is restricted to prevent wire intrusion, then safety is improved, but design flexibility deteriorates

Engineering Contradiction:

ImprovesafetyVSAvoidlayout flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

By segmenting the gap into multiple regions with dead ends, the invention eliminates the need for restricted connector layouts. Wires are trapped in dead end regions regardless of connector position, allowing flexible circuit board and connector arrangements while maintaining safety.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The protrusion and recess structures create preliminary barriers that intercept wires before they can reach the circuit board. This preliminary action of trapping wires in dead end regions eliminates the need for preventive layout restrictions, enabling flexible design arrangements.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11239582B2Electrical apparatus having entrapping structure

Publication Date: 2022.02.01 TE CONNECTIVITY JAPAN GK

AI summary

An electrical apparatus includes an electrical connector having a plurality of terminals and a connector housing retaining the terminals, a case containing the electrical connector, a circuit board electrically connected with the terminals, and an entrapping structure corresponding to at least a portion of a gap between the connector housing and the case. The entrapping structure has a dead end with an opening facing the gap.