Plug Connector Vibration Isolation via Play-Free Wire Fixing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing plug connectors in automobiles and industrial applications face issues with vibrations causing fretting corrosion and contact interruptions due to the transmission of stresses and vibrations from the electrical line to the connector housing, leading to increased resistance and wear, and complex, costly manufacturing processes.
Innovation Solution
The solution involves designing the connector housing to accommodate a separate component for fixing the electrical conductor's end region without play, allowing for decoupling from external forces and vibrations, using either non-positive or positive connections, such as gluing or ribbed structures, to ensure a play-free positional fixation, which simplifies manufacturing and reduces costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the contact partner is fixed in the chamber using tabs for primary locking, then the contact partner is prevented from moving out of the connector housing, but the contact partner can still move within the chamber relative to the connector housing due to vibrations and stresses
Solution Approach 1:
The patent introduces a separate fixing means (9) as an intermediary component between the line end region and the connector housing. This intermediary element provides play-free fixation while isolating the contact partner from vibrations and stresses transmitted through the line, thereby preventing fretting corrosion and contact interruptions.
Solution Approach 2:
The patent divides the fixation function into separate components: the connector housing (2), the line (4), and a separate fixing means (9). This segmentation allows each component to perform its specific function optimally - the fixing means provides vibration isolation while the contact partner maintains electrical contact, resolving the contradiction between stability and vibration protection.
2Force
If strain relief measures are taken to eliminate tensile and compressive stresses on the line, then these stresses are eliminated, but vibrations from the line are still transmitted to the contact partner and mating connector
Solution Approach 1:
The fixing means (9) acts as a vibration-damping intermediary that decouples the contact partner from vibrations in the line. While strain relief measures address tensile and compressive stresses, the fixing means specifically targets vibration transmission by providing a play-free but vibration-isolating connection point.
3Reliability
If the connector housing is molded directly around the end area of the line to fix it, then the line is fixed and strain relief is achieved, but the manufacturing process becomes extremely complex and costly
Solution Approach 1:
The patent separates the fixation function from the connector housing structure by using a distinct fixing means (9). This allows the connector housing to be manufactured using standard injection molding processes, while the fixing means can be separately produced and installed, dramatically simplifying manufacturing compared to direct overmolding of the line end.
Solution Approach 2:
By introducing the separate fixing means as an intermediary component, the patent avoids the need for complex direct integration of line fixation into the connector housing mold. The fixing means serves as a bridge that provides reliable fixation while maintaining manufacturing simplicity.
4Ease of operation
If the contact partner is allowed to move freely within the chamber, then assembly is easier, but the contact partner is susceptible to damage from vibrations and forced canting
Solution Approach 1:
The fixing means (9) provides a controlled fixation that prevents excessive movement and vibration damage while maintaining ease of assembly. It acts as an intermediary that guides the line end region into proper position and secures it play-free, balancing assembly simplicity with contact durability.
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 approach effectively prevents vibration transmission to the contact area, reducing fretting corrosion and surface wear, enhancing contact reliability and longevity while simplifying production and reducing costs, making it suitable for harsh environments like automobiles and high-vibration industrial settings.
Implementation Method 1
The means for fixing the position are designed to act in a non-positive and/or positive manner
Implementation Method 2
The means for fixing the position are designed to act in a non-positive and/or positive manner
Implementation Method 3
in order to decouple the electrical conductor from forces acting on the line
Data Source
Figure 1~2
AI summary
The connector (1) has a plug-in connector housing (2) with a chamber for accommodation of an end area of a wire, where the wire has an electrical conductor (5), an outer sheath and a contact zone (7) for accommodation of a counter plug-in connector. A wire fixing unit (9) is provided at the plug connector housing for play-free position-fixing of the end area of the wire within the chamber to decouple the electrical conductor from force that acts on the wire.