Low Height Connector Molding L-Shaped Wire
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Solution Overview
Problem
Existing connectors with L-shaped high-voltage electric wires require protectors to achieve downsizing, which complicates the process due to the wire's resilience and necessitates separate components, making it difficult to form low-height connectors without altering existing terminals or housing shapes.
Innovation Solution
A method involving the removal of insulating coverings from specific parts of the electric wire, bending these parts, joining a terminal, and molding the wire with a housing to create a low-height connector without the need for a protector, allowing for precise shaping and cost reduction by using existing terminals and components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a protector is used to downsize the connector, then the connector height is reduced, but the device complexity increases due to additional separate components
Solution Approach 1:
The patent merges the protector function with the housing by forming an integrated structure where the housing directly contains the L-shaped electric wire without requiring a separate protector component. This is achieved by designing the housing with specific geometric features that provide the necessary containment and structural support, eliminating the need for additional parts while maintaining the downsized connector height.
Solution Approach 2:
The housing is designed to perform multiple functions: it serves as both the structural container and the protector element. By integrating the protective function into the housing itself, the design eliminates separate protector components while maintaining both structural integrity and protection of the L-shaped wire, thereby reducing overall device complexity.
2Length of stationary object
If the high-voltage electric wire is forcibly bent into an L-shape, then the connector height is reduced, but the manufacturing difficulty increases due to the wire's high resilience
Solution Approach 1:
The patent applies preliminary action by pre-bending the high-voltage electric wire into an L-shape before assembling it into the housing. This pre-forming process allows the wire to be shaped while accessible, and the bent wire is then secured in place within the housing, making the bending operation easier to perform and control compared to attempting to bend the wire after assembly.
Solution Approach 2:
The patent applies local quality by providing support and constraint at specific locations within the housing to maintain the L-shape of the wire. The housing includes features such as ribs or support structures positioned at critical points to prevent springback and maintain the desired geometry, making the bending process more manageable by providing localized support where needed.
3Ease of manufacture
If a thick rib is provided on the protector to enable bending against repulsion, then the wire can be bent, but the device complexity increases
Solution Approach 1:
The patent merges the rib structure into the housing itself rather than making it a separate protector component. The housing includes integrated ribs or support features that provide the necessary structural reinforcement to enable wire bending while maintaining a unified, simpler overall structure without requiring separate protected components.
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
This approach enables the production of low-height connectors using existing terminals without a protector, reducing assembly complexity and costs, while allowing for precise bending and accurate shaping without deforming the wire, thus achieving downsizing without the need for additional space or components.
Implementation Method 1
forming the electric wire into a predetermined shape in which the first part of the electric wire is bent
Data Source
AI summary
A method of producing a low height connector, includes: removing an insulating covering from a first part of an electric wire; forming the electric wire into a predetermined shape in which the first part of the electric wire is bent; joining a terminal to a second part of the electric wire; and molding the electric wire to surround at least the first part and the second part of the electric wire with a housing to obtain the low height connector.