Sliding Automotive Lamp Connector for Misalignment Compensation
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Solution Overview
Problem
The complex and cumbersome connection of electrical components in automotive lamps due to limited space and misalignment issues, which requires manual intervention and additional cable length, leading to reduced production rates and increased manufacturing costs.
Innovation Solution
An electrical connector with a housing that allows sliding and adjustable motion within a panel, featuring multiple members for compensating misalignments and providing flexibility, enabling easier and automated connection of components without the need for excessive cable length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual connection of components is performed, then connection flexibility is improved, but production rate decreases and additional cable length is required
Solution Approach 1:
The connector housing is designed with dynamic movement capabilities, allowing it to slide and adjust position within the panel opening during the connection process. This dynamic adjustment enables automated connection systems to accommodate misalignments and tolerance variations without requiring manual intervention, thereby maintaining high production rates while achieving reliable connections
2Adaptability or versatility
If additional cable length is provided, then connection leeway is improved, but space consumption increases and cable damage risk increases
Solution Approach 1:
Instead of providing additional cable length in the traditional linear direction, the invention introduces movement freedom in multiple dimensions by allowing the connector housing to slide within the panel opening. This dimensional approach to adjustment space enables connection leeway without increasing overall cable length or consuming additional space within the lamp assembly
3Device complexity
If connector position is fixed, then structural simplicity is improved, but alignment compensation capability decreases
Solution Approach 1:
The connector housing incorporates sliding members that enable controlled movement within the panel opening, allowing the connector to dynamically adjust its position to compensate for misalignments between connecting components. This dynamic adjustment mechanism achieves precise alignment compensation while maintaining relatively simple connector construction
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 1E~2A
AI summary
An electrical connector for an automotive lamp, comprising: a connecting module with electrical terminals; and a housing adapted for insertion, together with the connecting module, into an opening of a panel in an insertion direction, and further adapted for sliding, together with the connecting module, within the opening of the panel in a sliding direction; wherein the insertion direction is perpendicular to the sliding direction; and wherein the housing comprises a first plurality of members adapted to allow motion of the housing, together with the connecting module, within the opening of the panel along a first motion direction. Also, an electrical connector assembly, a method for producing an electrical connector, and a method for electrical connection in an automotive lamp.