Foldable Insulator Plug Assembly for Compact Connector Integration
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Solution Overview
Problem
The assembly and testing of electrical plugs and sockets are labor-intensive and difficult due to the manual identification and insertion of pins into small, misaligned holes, especially in complex wiring looms for vehicles where space is limited and alignment is challenging.
Innovation Solution
An insulator component with movable segments that can be unfolded for easy pin insertion and folded for compact placement within a housing, featuring pin retaining means and machine-readable markings for simplified assembly and verification, allowing automated pin insertion and reduced in-situ testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If pins are inserted into small holes in a compact insulator, then the connector fits in limited space, but alignment becomes difficult and assembly is labor-intensive
Solution Approach 1:
The insulator is divided into multiple segments that can be moved relative to each other. During assembly, segments are positioned to provide large alignment tolerances for pin insertion, then folded together to form the compact final structure. This segmentation allows the insulator to provide both easy assembly and compact fitment.
Solution Approach 2:
The insulator transitions from a static compact structure to a dynamic multi-position structure during assembly. Segments are movable during assembly to facilitate pin insertion, then fixed in the folded position to achieve compactness. This dynamic approach resolves the contradiction between assembly ease and compactness.
2Manufacturing precision
If pins are inserted manually into small holes, then precise alignment is required, but this increases assembly time and labor intensity
Solution Approach 1:
The insulator segments are pre-positioned and pre-aligned before pin insertion. Machine-readable markings are pre-applied to guide pin placement. This preliminary preparation eliminates the need for precise alignment during the actual pin insertion process, enabling faster assembly without sacrificing precision.
Solution Approach 2:
Machine-readable markings serve as an intermediary between the insulator structure and the pin insertion process. These markings provide visual guidance that simplifies alignment, acting as a mediator that bridges the gap between the complex insulator structure and the simple pin insertion action.
3Adaptability or versatility
If connectors are assembled in-situ in vehicle, then routing flexibility is achieved, but assembly difficulty increases due to imperfect environment
Solution Approach 1:
The insulator is segmented and collapsible, allowing it to be compressed to a small size for routing through tight spaces in the vehicle. Once positioned, the segments are expanded to their functional configuration. This segmentation enables both easy routing and easy assembly in the vehicle environment.
Solution Approach 2:
The insulator transitions from a compact dynamic state during routing to a stable functional state during assembly. This dynamic capability allows the connector to adapt to different assembly environments, making it equally easy to assemble whether on a layout board or in-situ in the vehicle.
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
A plug assembly in which the insulator part can be moved from an unfolded state to a folded state. The insulator may be utilised in the unfolded state for assembly of a wiring loom, and then folded into the folded state for insertion into a connector body.