Plug Connector Carrier Element for Conductor Fixation
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Solution Overview
Problem
Existing plug connectors require high precision and cost in manufacturing due to the need for precise alignment and secure fixation of exposed electrical conductors within a plastic housing, especially in series production, leading to increased costs and potential fraying issues with stranded conductors.
Innovation Solution
The electrical conductor is arranged and fixed around a carrier element, which can be manufactured independently of the cable, with separate receiving and support areas for the conductor and cable, respectively, allowing for simpler assembly and reduced manufacturing complexity, and avoiding protrusion into the contact area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the exposed electrical conductor is fixed in a plastic housing to form a contact area, then the structure is simplified and no additional contact partner is needed, but high precision manufacturing is required which increases costs
Solution Approach 1:
A support element is introduced as an intermediary component between the electrical conductor and the plastic housing. The support element has a receiving area that holds the conductor and a support area that interfaces with the housing, acting as a mediator that simplifies the overall structure while maintaining manufacturing precision requirements in a localized, manageable area.
Solution Approach 2:
The connector is divided into functional segments: the plastic housing, the support element with distinct receiving and support areas, and the electrical conductor. This segmentation allows each component to be optimized independently, with the support element bearing the precision requirements rather than the entire housing-conductor assembly.
2Reliability
If the exposed electrical conductor is secured in the plastic housing, then secure fixation is achieved, but the manufacturing costs increase due to precise tool manufacture and quality control
Solution Approach 1:
The support element serves as a mediator that concentrates the fixation function in a dedicated component. The receiving area of the support element provides secure fixation for the conductor through designed geometric relationships, while the support area interfaces with the housing, separating the security requirements from the housing manufacturing process.
Solution Approach 2:
The support element is designed and prepared in advance with the receiving area configured to hold the conductor. This preliminary preparation allows the conductor to be inserted and fixed in a controlled manner before final assembly with the housing, ensuring secure fixation while simplifying the overall manufacturing process.
3Area of stationary object
If the electrical conductor end protrudes into the contact area, then contact area is formed, but tilting during assembly occurs causing fraying of stranded conductors
Solution Approach 1:
The support element acts as an intermediary that positions the electrical conductor's end area at the precise location where the contact area is needed, without allowing the conductor to protrude freely. The geometric relationships of the support element prevent tilting during assembly, protecting the stranded conductor from fraying while maintaining adequate contact area.
Solution Approach 2:
The support element provides localized structural support and positioning exactly where needed - at the end area of the conductor. The receiving area and support area are designed with specific geometric relationships that locally control the conductor's position and orientation, preventing fraying only where it matters most without affecting the overall connector design.
Data Source
AI summary
The connector (1) has an electrical conductor (4) with cables (2), where an end area of the electrical conductor forms a contact area for a contact partner, a two way pin-and-socket connector and the cable is fixed at a carrier element (5). An electrical conductor is arranged and fixed at the front side around the carrier element. The carrier element has a receiving region (6) for the establishment of an electrical conductor.