Parallel-Wire Connector Housing to Prevent Tube Tilt
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Solution Overview
Problem
The existing shield connector design suffers from a reduction in dimensional accuracy due to the tilt of lead-out tube portions during injection molding, which affects the housing's precision and wire orientation.
Innovation Solution
A connector design featuring terminals and wires embedded in a resin housing with projecting portions and coupling portions that restrict tilt, ensuring accurate dimensional stability and reduced resin usage, while also incorporating adhesive application to prevent water intrusion and thermal shrinkage issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lead-out tube portions are cantilevered from the lead-out portion body, then the structure is simple and easy to manufacture, but the lead-out tube portions are easily tilted after injection molding, reducing dimensional accuracy
Solution Approach 1:
The housing is divided into a lead-out portion body and multiple separate lead-out tube portions. Each lead-out tube portion is individually formed and then inserted into the lead-out portion body, rather than being formed as a single cantilevered structure. This segmentation allows each tube portion to be precisely positioned and fixed, preventing tilt while maintaining manufacturing simplicity.
Solution Approach 2:
The lead-out tube portions are prepared in advance as separate components with predetermined shapes and dimensions. Before injection molding, these pre-formed tube portions are inserted into the lead-out portion body and positioned accurately. This preliminary preparation ensures that the tubes maintain their intended orientation and position throughout the molding process, preventing dimensional accuracy reduction.
2Device complexity
If lead-out tube portions are cantilevered from the lead-out portion body, then the structure is simple, but the extending direction of wires becomes inconsistent, affecting connector performance
Solution Approach 1:
The housing structure is segmented into the lead-out portion body and individual lead-out tube portions. Each tube portion is separately formed with a specific geometry designed to guide wires in a consistent direction. This segmentation allows precise control over the orientation of each tube, ensuring that all wires emerge in the intended direction regardless of the overall structural simplicity.
Solution Approach 2:
Each lead-out tube portion is designed with specific local geometric features (such as curved surfaces or angled sections) that are optimized for wire guidance. These local quality variations in each tube portion ensure that wires passing through them maintain consistent extending directions, while the overall housing structure remains simple and easy to manufacture.
Data Source
AI summary
A connector 10 includes a plurality of terminals 20 extending in parallel to each other, a plurality of wires 30 to be connected to the respective terminals 20 and parallel to each other, and a housing 40 made of resin, the plurality of terminals 20 and the plurality of wires 30 being embedded in the housing. The housing 40 includes a body portion 50 for collectively covering the plurality of terminals 20, a plurality of projecting portions 60 projecting from the body portion 50 to individually cover the plurality of wires 30 and provided at intervals from each other in a first direction Z, and a coupling portion 63 for coupling two projecting portions 60 adjacent to each other in the first direction Z.