Piercing Connector Pre-Locking Structure for Safer Wire Assembly
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Solution Overview
Problem
Existing electrical connectors face issues with structural design leading to increased packaging costs and potential electrical accidents due to manual assembly errors, as they require a cover shell and plastic shell to be tightly assembled to prevent collisions, and the crimped external wire needs to be manually assembled, which is prone to mistakes.
Innovation Solution
A piercing electrical connector design featuring a wire end connector with a wire end terminal and wire cover that includes a clasping mechanism to prevent tight assembly or separation, allowing for easy connection and disconnection of cable wires, reducing assembly costs and improving production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cover shell and plastic shell are tightly assembled to prevent collisions among connectors, then the connectors are protected during transportation, but the packaging costs are significantly raised
Solution Approach 1:
The connector is divided into two main parts: a cover shell and a plastic shell. These parts are designed to be separable rather than permanently fixed together, allowing them to be packaged independently. This segmentation eliminates the need for expensive tight assembly packaging while maintaining protection during transportation.
Solution Approach 2:
The connector components are pre-assembled to a degree that ensures they remain connected during use, but the design inherently prevents separation during normal handling. This preliminary connection action eliminates the need for additional protective packaging measures.
2Ease of operation
If manual assembly of crimped external wire into the plastic shell body is used, then flexibility in assembly is maintained, but mistakes are easily made leading to electrical accidents
Solution Approach 1:
The connector incorporates a self-assembling mechanism where the crimped external wire is automatically secured into the plastic shell body through the connector's structure. The design includes features such as pre-positioned wire guides and self-locking mechanisms that eliminate the need for manual assembly operations, thereby preventing human error while maintaining operational simplicity.
Solution Approach 2:
The wire crimping and positioning is performed as a preliminary action during connector manufacturing. The external wire is pre-crimped and pre-positioned in the correct location, so that during assembly, no additional manual manipulation is required. This preliminary preparation ensures correct positioning every time without relying on operator skill.
3Productivity
If the wire cover and wire end body are easily separated for connection and disconnection, then production efficiency is improved, but the connectors may become loose or disconnected during transportation
Solution Approach 1:
The connector employs a dynamic locking mechanism that adapts between two states: during assembly, the cover shell and plastic shell can be easily connected and disconnected; during operation, the mechanism automatically transitions to a locked state that prevents separation. This dynamic behavior allows the connector to provide both ease of assembly and transportation stability.
Solution Approach 2:
The connector design includes preliminary anti-action features such as engagement protrusions and recesses that automatically lock the cover shell and plastic shell together upon connection. These features create a predetermined resistance to separation forces, preventing accidental disconnection during transportation while maintaining easy assembly through the same mechanism.
Data Source
AI summary
A piercing electrical connector includes a wire end connector. The wire end connector has a wire end body, a wire end terminal, and a wire cover engaged with the wire end body. The wire cover has a wire holding hole, and the wire end terminal has a piercing portion. The wire cover further has a clasping plate, a clasping arm and a first clasping head. The wire end body has a clasping groove, a clasping hole, a protrusion located in the clasping groove, a pre-locking groove and a locking groove that communicate with the clasping hole. When the wire end connector needs to be transported, the first clasping head extends into the pre-locking groove, and the protrusion abuts against a free end of the clasping plate so that the wire cover and the wire end body are pre-assembled together, and the piercing portion does not pierce a cable wire.