Modular Housing Connection Device for Electrical Loads
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Solution Overview
Problem
Existing electrical connection devices face manufacturing challenges due to variability in conductor positioning, requiring specific molding processes and resulting in high scrap rates and extra cleanup work.
Innovation Solution
The connection device is composed of separately formed housing portions and conductors, where the conductors are attached to a first housing portion and secured by additional housing portions, forming a stable assembly that resists movement in multiple directions, eliminating the need for in-situ molding and reducing scrap rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conductors are molded in situ about the conductors to form the insulative portions of the connection device, then the connection device can be manufactured in a single integrated process, but the manufacturing process becomes subject to variability and results in high scrap rates and extra cleanup work
Solution Approach 1:
The housing is divided into multiple separately manufactured portions (first housing portion, second housing portion, third housing portion) that are assembled together. The conductors are attached to the first housing portion before assembly, allowing precise conductor positioning to be achieved in the separate components rather than attempting to mold everything in a single integrated process.
2Productivity
If conductors are held in a particular orientation on a support and molded in situ, then the connection device can be formed as an integrated unit, but the process requires extra cleanup work and has high scrap rate
Solution Approach 1:
The conductors are attached to the first housing portion in advance, before the housing portions are assembled together. This preliminary attachment allows the conductors to be positioned and secured properly beforehand, eliminating the need for cleanup work after molding and reducing scrap rates from molding variability.
3Manufacturing precision
If housing portions are formed separately and assembled together, then manufacturing variability and scrap rates are reduced, but the device complexity increases
Solution Approach 1:
The multiple housing portions (first, second, and third housing portions) are assembled together to form a complete housing that contains and secures the conductors. The mounting structures and retention features are distributed across these portions but work together as an integrated system to achieve precise conductor positioning and secure retention.
Data Source
AI summary
A connection device employs a plurality of housing portions that are formed separately from one another and further includes a plurality of conductors. The plurality of conductors are situated on a first housing portion, and a second housing portion and a third housing portion are then affixed at opposite ends of the first housing portion to retain the conductors in place on the first housing portion. The first, second, and third housing portions, being connected together, are then received in a receptacle of a fourth housing portion to form the connection device. The conductors each have an elongated shank that is received in an elongated channel formed in the first housing portion before the second and third housing portions are attached thereto.