Variable Wire Strain Relief Connector With V-Shaped Supports
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Solution Overview
Problem
Existing strain relief structures for electrical connectors are inadequate for large diameter wires, such as high current battery cables, as they cannot effectively accommodate variations in wire diameter and do not provide sufficient protection against vibration and external forces without bending the wire, which is not feasible for less pliable cables.
Innovation Solution
A connector design featuring a housing with V-shaped rigid wire supports and resiliently deflectable supports that engage the wire's insulation coating, allowing for secure positioning and strain relief without bending, accommodating variations in wire diameter through a combination of V-shaped supports and deflectable beams that lock into place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If prior art strain relief structures are used with large diameter wires, then the structure is simple, but the strain relief effectiveness deteriorates due to inability to bend and position the wire
Solution Approach 1:
The patent employs resiliently deflectable support beams that can dynamically adapt to different wire diameters. These beams are designed to deflect under the weight and diameter of the wire, then resiliently return to their original position, providing consistent strain relief across varying wire sizes without requiring complex adjustment mechanisms.
Solution Approach 2:
The invention changes the physical state and properties of the support structure by using resiliently deflectable beams instead of rigid supports. This allows the support structure to adapt its parameters (deflection amount, contact pressure) based on the wire diameter, effectively resolving the contradiction between structural simplicity and strain relief effectiveness for large diameter wires.
2Reliability
If rigid structures are used to position the wire, then the strain relief is effective for small diameter wires, but it fails for large diameter wires with diameter variations
Solution Approach 1:
The resiliently deflectable support beams provide a dynamic solution that automatically adapts to different wire diameters. When a wire is placed on the beams, they deflect to accommodate the wire's weight and diameter, then maintain contact pressure to prevent movement. This dynamic behavior enables the same structure to effectively support wires with varying diameters without requiring adjustment or complex mechanisms.
3Power
If large diameter wires are used, then the current carrying capacity is improved, but the ease of positioning and bending for strain relief deteriorates
Solution Approach 1:
The resiliently deflectable support beams eliminate the need to bend large diameter wires for strain relief. The beams dynamically adapt to the wire's position and diameter, providing support and preventing movement through their deflection and resilient return. This makes the strain relief process as easy as placing the wire on the beams, regardless of the wire's diameter or pliability.
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
The solution effectively prevents relative movement between the wire and terminal fitting, maintaining a stable electrical connection under vibration and external forces, regardless of wire diameter variations, making it suitable for large diameter high current cables.
Implementation Method 1
resiliently deflectable supports that engage the wire's insulation coating
Data Source
AI summary
A connector (10) includes a housing (12) with a terminal receiving cavity (22) and a wire receptacle (24) communicating with the terminal receiving cavity (22). The wire receptacle (24) includes at least one V-shaped wire support (40) for supporting a wire (50) at two circumferentially spaced positions on the wire (50). A cover (60) is mounted to the housing (12) and has at least one resiliently deflectable strain relief beam (70) that biases the wire (50) into the wire receptacle (24).