Stacked Connector Space Reduction via Split Modular Design
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Solution Overview
Problem
The increasing number of circuits in vehicles leads to a rise in the number of joint connectors, resulting in increased installation space requirements, which is a challenge due to limited space in vehicles, and complicates the manufacturing process of wire harnesses.
Innovation Solution
A stacked connector system is developed by joining split connectors with locking portions, allowing for dispersion during manufacturing and concentration during vehicle arrangement, reducing space requirements and improving manufacturability through a split and stacked form design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of joint connectors is increased to accommodate more circuits, then the number of splice circuits increases, but the installation space increases
Solution Approach 1:
Multiple joint connectors are integrated into a single stacked connector assembly where multiple split connectors are stacked in the vertical direction and connected through a common base connector. This merging of multiple separate connectors into one compact unit reduces the overall installation space while maintaining the required number of splice circuits.
Solution Approach 2:
The connector design transitions from a horizontal arrangement to a vertical stacking configuration. By arranging multiple split connectors in the vertical direction (stacking direction) rather than spreading them horizontally, the patent utilizes the vertical dimension to reduce the footprint area occupied by the wire harness system.
2Area of stationary object
If connectors are concentrated to reduce installation space, then space usage decreases, but manufacturing difficulty increases
Solution Approach 1:
The stacked connector is divided into multiple independent split connectors that can be manufactured separately and then assembled. Each split connector contains a specific number of terminals and can be produced as a modular unit, allowing for easier manufacturing and quality control compared to producing a single large integrated connector.
Solution Approach 2:
The base connector serves multiple functions: it provides the foundational structure for stacking, contains common terminals that connect to multiple split connectors, and facilitates the assembly process. This multi-functional design simplifies the overall manufacturing process while achieving space reduction.
3Area of stationary object
If multiple split connectors are stacked to reduce space, then installation space decreases, but locking and securing complexity increases
Solution Approach 1:
The locking mechanism is designed to automatically engage when split connectors are stacked. The locking protrusions and locking grooves self-align and self-lock without requiring additional fastening operations or complex securing mechanisms, thereby reducing assembly complexity while maintaining secure connections.
Solution Approach 2:
The locking protrusions of upper split connectors nest into the locking grooves of lower split connectors in a hierarchical manner. This nested arrangement provides a systematic and straightforward locking mechanism that scales with the number of stacked connectors without proportionally increasing complexity.
Data Source
AI summary
An object is to provide a technique by which a space in a vehicle in which a wire harness including a plurality of splice circuits is arranged can be reduced and good manufacturability at the time of manufacture can be achieved. A stacked connector is formed by joining a plurality of split connectors to each other. The split connectors each include a split connector housing provided with a plurality of terminal receiving chambers and a plurality of terminal-equipped electric wires that each include a terminal received in the terminal receiving chamber and an electric wire to which the terminal is connected. At least one of the split connector housings is provided with a locking portion having a protruding shape that protrudes outward to be capable of locking the terminal-equipped electric wire received in the split connector housing of a joining counterpart.