Rounded Connector Assembly Wire Tension Reduction

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Solution Overview

Problem

Existing connector assemblies with rectangular end corners and flat wire harness inlets cause sudden wire bending, leading to increased tension, contact failures, and interference with external structures.

Innovation Solution

A connector assembly with rounded edges and a guide groove at the end portion to guide wires curved to match the round shape, reducing tension and preventing interference with external structures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a rectangular structure with flat wire harness inlet is used, then manufacturing is simple, but wire tension increases and contact failure occurs

Engineering Contradiction:

Improveconnector structure simplicityVSAvoidwire contact reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The wire harness inlet end is formed with a round shape instead of a rectangular structure, and guide grooves with curved surfaces are provided to guide wires along a curved path. This curvature allows wires to bend gradually rather than suddenly, reducing wire tension and preventing contact failure while maintaining manufacturing feasibility.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Reliability

If an inclined surface is added to guide wires, then wire bending is improved, but edge sharpness causes interference with external structures

Engineering Contradiction:

Improvewire bending controlVSAvoidinterference with external structure

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Instead of using an inclined surface with a sharp edge, the invention uses a round-shaped inlet end with guide grooves that have curved surfaces. This curved structure guides wires smoothly without creating sharp edges that could interfere with external structures, while still effectively controlling wire bending.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Reliability

If wires are curved to match round connector shape, then wire tension is reduced, but interference with external structures may occur

Engineering Contradiction:

Improvewire tension reductionVSAvoidinterference with external structure

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Guide grooves are provided as intermediary structures that receive and constrain wires along a curved path matching the round connector shape. These grooves act as mediators between the wire and the external structure, allowing the wire to be curved and tension-reduced while preventing direct contact and interference with external structures.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP3648261B1Rounded connector assembly

Publication Date: 2023.03.01 LG ENERGY SOLUTION LTD

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AI summary

The present invention relates to a connector assembly with rounded edges, in which an end of a female connector is formed in a round shape and a guide groove having an inner dimension receiving a wire is formed at an end portion to guide the wire to be curved to correspond to the round shape at a wire harness inlet end and guide the curved wire to be received in the guide groove, thereby guiding reduction of tension of the curved wire and prevention of interference with an external structure.