In-Vehicle Connector Assembly With Nested Socket Dust Protection

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Solution Overview

Problem

Existing connector assembly methods for in-vehicle equipment are complex, lead to increased size and component costs, and fail to ensure dust resistance, especially in harsh environments, due to the use of screwing, soldering, or cable connections.

Innovation Solution

A connector assembly method where a lead from an external connector is inserted into a socket opening of an internal connector, allowing for a simplified connection process while ensuring dust resistance by housing the contact terminal and tip end of the lead within the socket opening.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If screwing, soldering, or cable connection methods are used to connect external connector and internal substrate, then connection reliability is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improveconnection reliabilityVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical connection methods (screwing, soldering, cable connection) with a spring-based elastic contact system. The spring element provides automatic mechanical engagement and electrical contact through elastic deformation, eliminating complex assembly processes while maintaining reliable connection through continuous contact force.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If traditional connection methods are used, then connection strength is improved, but equipment size increases

Engineering Contradiction:

Improveconnection strengthVSAvoidequipment size

Core Design Contradiction:

StrengthVSVolume of moving object

Solution Approach 1:

The patent integrates the connection function within the existing connector housing structure. The spring element is nested inside the connector assembly, and the lead wire is routed through the housing, allowing the connection mechanism to occupy minimal space within the overall equipment volume while maintaining adequate connection strength through elastic contact.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Ease of manufacture

If exposed terminals are used for connection, then ease of assembly is improved, but dust resistance deteriorates

Engineering Contradiction:

Improveassembly easeVSAvoiddust resistance

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent employs the connector housing as a protective enclosure that completely covers the spring element and terminal contact areas. This shell structure prevents dust and contaminants from reaching the electrical contacts while allowing automatic assembly through the elastic engagement mechanism that guides components into proper alignment during insertion.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS20230275370A1Connector assembly method, in-vehicle equipment assembly method, connector assembly, and in-vehicle equipment

Publication Date: 2023.08.31 HIROSE ELECTRIC CO LTD

AI summary

A connector assembly method which includes connecting an external connector fixed to a case of equipment and an internal connector on an internal substrate in the case. A lead extending inward of the case is provided at the external connector, a contact terminal is provided in a socket opening formed at the internal connector, and the connecting the external connector and the internal connector includes inserting a tip end side of the lead into the socket opening in such a manner that the socket opening of the internal connector and a tip end of the lead of the external connector relatively approach each other.