Perpendicular Electrical Connector for Wiring Harnesses
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Solution Overview
Problem
Existing electrical connectors for wiring often lack efficient and secure methods for interconnecting flat wires, especially in applications requiring strain relief and weatherproofing, and do not easily accommodate various external electrical components like sensors and lighting devices.
Innovation Solution
The electrical connector design features insulated wires with webbing for structural integrity, spring features for secure engagement, snap features for assembly, and seals for weatherproofing, along with secondary locks for secure connections to external components, allowing for flexible integration with sensors and lighting devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical connectors are used for flat wires, then basic electrical connection is achieved, but strain relief and secure engagement are insufficient
Solution Approach 1:
The connector is divided into a housing and a separate engagement component with spring features. The spring features are distributed at multiple locations to engage with stripped portions of wires at different positions, providing localized secure engagement without requiring a completely complex integrated structure.
Solution Approach 2:
Spring features are incorporated into the engagement component, providing dynamic elastic deformation capability. The springs can deflect to accommodate wire position variations and provide continuous contact pressure, ensuring reliable electrical connection and strain relief under varying conditions.
2Object-affected harmful factors
If weatherproofing is added to electrical connectors, then environmental protection is improved, but assembly complexity increases
Solution Approach 1:
The seal is integrated directly into the housing structure, merging the sealing function with the structural component. This eliminates the need for separate sealing components and reduces assembly steps, as the seal is already positioned within the housing during manufacturing.
Solution Approach 2:
The seal is positioned within the housing to automatically engage with the engagement component when assembled. The sealing action occurs self-automatically during the normal assembly process without requiring additional sealing operations or adjustments.
3Adaptability or versatility
If multiple housing portions are used for assembly, then modularity and adaptability are improved, but assembly steps increase
Solution Approach 1:
The engagement component with spring features is pre-assembled within the housing structure. This preliminary assembly ensures proper positioning and pre-tensioning of springs before the final connection to the wire bundle, reducing adjustment time during field assembly.
Solution Approach 2:
Mechanical snap-fit features are incorporated between housing portions to replace complex fastening systems. The snap features provide quick mechanical interlocking that can be assembled by hand or simple tools, significantly reducing assembly time while maintaining structural integrity.
4Reliability
If spring features are added for wire engagement, then electrical connection reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The spring features are integrated into the engagement component housing, merging the electrical contact function with the mechanical engagement function. This consolidation reduces the total number of separate components and simplifies the manufacturing process by reducing assembly steps.
Solution Approach 2:
The spring features are designed with optimized geometric parameters and material properties to achieve the required contact pressure and elasticity. By carefully selecting spring dimensions and material characteristics, reliable electrical connection is achieved without requiring overly complex spring mechanisms.
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 design provides reliable electrical connections, strain relief, and weatherproofing, enabling efficient use in diverse applications while simplifying the integration of sensors and lighting devices, and facilitating easier handling and assembly of wiring harnesses.
Implementation Method 1
The second housing portion includes first and second spring features respectively configured to engage the stripped portions
Implementation Method 2
The housing includes at least one snap feature that removably connects the first and second housing portions
Implementation Method 3
The electrical connector includes first and second seals that respectively support the first and second housing portions
Data Source
AI summary
An electrical connector includes wiring with first and second wires. Each of the first and second wires have a conductor covered in insulation. The insulation includes webbing that interconnects the first and second wires to one another. The first and second wires have a stripped portion that exposes the conductors. A housing has first and second housing portions. The first housing portion receives the stripped portions. The second housing portion includes first and second spring features respectively configured to engage the stripped portions of the first and second wires when the first and second housing portions are secured to another in an assembled connector condition.