Two-Part Flat Connector Housing to Prevent Conductor Kinking
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Solution Overview
Problem
Existing flat plug connectors often result in kinking and damage to conductors due to plastic deformation during insertion, leading to a reduced service life.
Innovation Solution
A two-part plug connector housing design that allows the conductor portion with a flexible flat conductor to be inserted without deformation, providing protection and support between the housing parts, which are fixable relative to each other, ensuring a secure and damage-free attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the conductor portion is inserted through a narrow opening of the flat plug connector, then the conductor can be securely connected to the plug connector housing, but the conductor suffers from kinking and plastic deformation
Solution Approach 1:
The plug connector housing is divided into two separate parts: an upper housing part and a lower housing part. The conductor portion is inserted between these two parts, allowing it to be secured without passing through a narrow opening. This segmentation eliminates the kinking problem while maintaining secure connection through the夹持 force between the housing parts.
Solution Approach 2:
The conductor portion acts as an intermediary element positioned between the upper and lower housing parts. Instead of forcing the conductor through a narrow opening, the housing parts are brought together to clamp the conductor, using the conductor itself as the medium that transfers the securing force while avoiding deformation.
2Strength
If tabs are arranged at the conductor portion to come into form-fit abutment with the plug connector housing, then the conductor can be securely attached, but the insertion process causes plastic deformation and damage
Solution Approach 1:
Instead of inserting the conductor through a narrow opening from one side, the invention inverts the approach by having the conductor positioned between two housing parts that are then brought together. The securing action occurs from both sides simultaneously, eliminating the need for forceful one-sided insertion and preventing plastic deformation of the tabs.
3Reliability
If a two-part plug connector housing is used to insert the conductor without deformation, then the conductor service life is improved, but the device complexity increases
Solution Approach 1:
The upper and lower housing parts are designed to be joined together to form an integrated plug connector housing assembly. While manufactured separately to avoid conductor deformation, these parts are combined through standard fastening methods, merging their functions to provide both the deformation-free insertion path and the secure clamping structure in a single unified device.
Data Source
AI summary
The present invention relates to a flat plug connector (10), a flat plug connector system (1) and a method for manufacturing a flat plug connector (10),wherein the flat plug connector (10) comprises a two-part plug connector housing (11) and a conductor portion (30) with a flexible flat conductor (110) for electrically conductive connection to contacts (70) of a complementary flat plug connector (50), wherein the conductor portion (30) with the flexible flat conductor (110) is arrangeable in the plug connector housing (11) without deformation, and wherein the conductor portion (30) with the flexible flat conductor (110) is arranged, at least in sections, between a first upper plug connector housing part (40) and a second lower plug connector housing part (20),wherein the first plug connector housing part (40) and the second plug connector housing part (20) are fixed relative to each other.