Connector Retainer With Helical Channels For Vibration Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connector assemblies fail to effectively retain conductors and prevent vibration-induced fretting corrosion, particularly in applications with temperature fluctuations, due to pinching or clamping mechanisms that can loosen over time.
Innovation Solution
A connector assembly featuring a cable retainer with helical channels that twist conductors by at least 90 degrees, providing an interference fit and reducing vibration transmission through a self-wrapping mechanism, while using additive manufacturing for toolless production and minimizing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pinching or clamping mechanisms are used to retain conductors, then initial retention strength is improved, but reliability deteriorates due to loosening over time under vibration and temperature fluctuations
Solution Approach 1:
The cable retainer features helical channels with curved geometry that twist conductors by at least 90 degrees. This curvature creates an interference fit that maintains constant retention pressure without loosening, resolving the contradiction between initial strength and long-term reliability under vibration and temperature changes.
Solution Approach 2:
The patent changes the geometric parameters of the retainer channels from straight to helical, creating a twisted path that transforms the retention mechanism. This parameter change enables the conductor to be mechanically locked through angular deviation, preventing loosening while maintaining strong retention.
2Object-affected harmful factors
If helical channels with at least 90 degrees twist are used, then vibration transmission is reduced and conductor isolation is improved, but device complexity increases
Solution Approach 1:
The helical channels incorporate curved geometry that twists conductors by at least 90 degrees, effectively isolating conductor motion from terminals and reducing vibration transmission. This curvature-based approach addresses the harmful vibration factor while the channels remain integral to the retainer body.
Solution Approach 2:
The cable retainer is formed as an integral component with the connector body through additive manufacturing, merging the retainer structure with the housing. This integration reduces overall device complexity despite the sophisticated helical channel geometry, as no separate retainer part is needed.
3Ease of manufacture
If additive manufacturing is used for production, then manufacturing complexity and material waste are reduced, but manufacturing precision requirements increase
Solution Approach 1:
The cable retainer and connector body are manufactured as a single integrated component using additive manufacturing technology. This merging eliminates the need for separate retainer parts and complex assembly operations, significantly easing manufacturing while the additive process inherently handles the complex helical channel geometry with required precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively isolates conductor motion from terminals, reducing fretting and plating wear, enhances reliability, and accommodates various cable sizes without interference, making it suitable for applications with temperature changes.
Implementation Method 1
providing an interference fit and reducing vibration transmission through a self-wrapping mechanism
Implementation Method 2
reducing vibration transmission through a self-wrapping mechanism
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A connector assembly (100) includes a conductor retainer (110) that is configured to relieve retain a conductor (102) within a connector body (108) of the connector assembly (100). The conductor retainer (110) causes the conductor (102) to helically twist at least 90 degrees about a longitudinal axis. A helical channel (112) may be defined in the conductor retainer (110) to cause the conductor (102) to helically twist. Multiple conductors (102) may be terminated within the connector assembly (100) and the conductor retainer (110) may define multiple helical channels (112). Some of the helical channels (112) may have a right hand helical twist while others have a left hand helical twist. A method (200) of manufacturing a connector assembly (100) with these features is also presented.