Vehicle Connector With Flexible Conductor Absorbing Vibrations
Solution Overview
Problem
Existing connectors used in vehicles face issues with assembly complexity and reduced contact reliability due to production tolerances and vibrations, which lead to wear and reduced conductivity between terminals.
Innovation Solution
A connector design featuring a housing with an L-like bent shape, flexible conductors with an external-force absorbing portion, and a shield shell for improved assembly ease and contact reliability, incorporating a front holder, conductor coupling fixed terminals, and a shield shell for effective vibration absorption and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid connections are used between terminals and housing, then structural strength is improved, but vibration transmission increases causing wear and reduced conductivity
Solution Approach 1:
The patent employs flexible printed circuit boards (FPC) as connection elements between terminals and housing. The FPC incorporates bending portions that allow controlled deformation to absorb vibrations while maintaining electrical connectivity. This flexible connection structure prevents vibration transmission that would otherwise cause wear and contact failure, thereby maintaining both structural integrity and contact reliability.
Solution Approach 2:
The patent changes the mechanical parameters of the connection structure by introducing compliant elements with specific bending radii and flexibility characteristics. The FPC is designed with controlled stiffness through its trace pattern, substrate thickness, and bending geometry, allowing it to deform elastically under vibration while maintaining sufficient mechanical strength for structural support.
2Reliability
If precise alignment features are added to accommodate tolerance, then contact reliability is improved, but assembly complexity increases
Solution Approach 1:
The patent replaces static rigid alignment features with dynamic flexible connections that can adapt to positional variations. The FPC's bending portions are strategically positioned to compensate for tolerance accumulation in the assembly direction, allowing the connection to maintain optimal contact geometry despite variations in component positioning, thereby simplifying assembly while ensuring reliability.
Solution Approach 2:
The FPC acts as an intermediary element between rigid components, providing both mechanical support and positional compensation. Its flexible nature allows it to bridge gaps caused by tolerance variations without requiring complex adjustment mechanisms or precision alignment features in the rigid components themselves.
3Ease of manufacture
If multiple separate components are used for housing and terminals, then manufacturing flexibility is improved, but assembly time increases
Solution Approach 1:
The patent combines multiple functions into integrated components where the housing structure incorporates terminal mounting features and the FPC integrates both electrical connection and mechanical support functions. This reduction in component count and simplification of assembly steps decreases assembly time while maintaining the manufacturing flexibility benefits of modular design.
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 connector allows for easy assembly and enhanced contact reliability by absorbing positional displacements and vibrations, preventing wear and ensuring consistent conductivity between terminals.
Implementation Method 1
the flexible conductor connecting the terminal to the other end of the fixed terminal, and including an external-force absorbing portion sagging between both ends of the flexible conductor
Implementation Method 2
the flexible conductor connecting the terminal to the other end of the fixed terminal, and including an external-force absorbing portion sagging between both ends of the flexible conductor
Data Source
AI summary
A connector including a housing which formed with a work opening in an outer surface on a side of an outer corner of the L-like bent shape of the housing, further includes a lid attached to the work opening, a fixed terminal configured to be inserted through the external-wire leading portion and accommodated in the housing, and a flexible conductor connecting the terminal to one end of the fixed terminal and including an external-force absorbing portion sagging between both ends of the flexible conductor. The other end of the fixed terminal is connected to a conductor of the external wire, and an intermediate portion of the fixed terminal is fixed to the housing and elongates along the axis of the external wire.