Wire Connector Interference Fit Sealing Stress Relief
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Solution Overview
Problem
Existing wire to wire connectors fail to simultaneously provide sufficient water resistance, stress cushioning, and visibility of the joining region between the cable outer sheath and the connector casing, while also ensuring reliable fixation and electrical connection of the conductive core and pin.
Innovation Solution
A wire to wire connector design featuring a core seal and core plug in an interference fit with the conductive core, crimping structures on the pin for secure electrical connection, and an overmoulded casing for stress relief and visibility, along with stop structures to prevent pin movement within the connector casing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If water resistance is enhanced at the cable entry position, then water or moisture cannot enter the connector casing, but stress cushioning capability and visibility of the joining region deteriorate
Solution Approach 1:
The connector is divided into distinct functional zones: a sealing region with the sealing member for water resistance, a transition region for stress cushioning, and a joining region for visibility. This segmentation allows each zone to optimize its specific function without compromising others.
Solution Approach 2:
A sealing member acts as an intermediary element between the cable outer sheath and the connector casing. It provides water sealing while its flexible material properties enable stress cushioning, and its transparent nature maintains visibility of the joining region.
2Illumination intensity
If visibility of the joining region is improved, then the region between cable outer sheath and connector casing can be observed, but water resistance and stress release capability deteriorate
Solution Approach 1:
The sealing member exhibits different local properties: it is transparent in the region affecting visibility, flexible in the region affecting stress cushioning, and sealing in the region affecting water resistance. This local differentiation of material properties resolves the contradiction.
3Strength
If stress cushioning is increased at the cable entry position, then excessive bending of the wire or cable is prevented, but water resistance and visibility of the joining region deteriorate
Solution Approach 1:
The sealing member is designed with dynamic flexibility to absorb stress and accommodate cable movement while maintaining its sealing and visibility functions. Its elastic properties allow it to deform under stress and return to its original shape, providing continuous stress cushioning.
4Reliability
If the position of conductive core and pin is made fixed within the connector casing, then reliable electrical connection is achieved, but water resistance, stress cushioning, and visibility deteriorate
Solution Approach 1:
The pin is pre-positioned and fixed within the connector casing before final assembly, ensuring reliable electrical connection from the outset. The sealing member is then installed to provide water resistance without disturbing the pre-established electrical connection.
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
Ensures reliable electrical connections, prevents water and moisture ingress, maintains cable integrity by preventing excessive bending, and ensures the visibility of the joining region, thereby enhancing the durability and performance of the connector.
Implementation Method 1
a core seal and a core plug being fitted round the insulator of each conductive core in an interference fit; the core seal and core plug of the conductive core being fitted in an interfering manner to an inner surface, defining the pin hole, of the connector casing
Implementation Method 2
a first crimping structure crimped to the core seal, a second crimping structure crimped to a conductive outer surface of the conductive core
Implementation Method 3
an overmoulded casing that is overmoulded on at least a part of the connector casing and on a part of an outer sheath of the cable
Implementation Method 4
a stop structure preventing the pin from moving in the longitudinal direction
Implementation Method 5
there must be water resistance at the position where the wire or cable extends into the connector casing, to prevent water or moisture from entering the connector casing
Data Source
Figure 1~2
Figure 3~4
Figure 5a~5f
AI summary
The present invention relates to a wire to wire connector (100), comprising: a cable (30), comprising at least one conductive core (34) and an insulator (36) surrounding the conductive core (34), with a core seal (40) and a core plug (50) being fitted round the insulator (36) of the conductive core (34) in an interference fit; a connector casing (10), defining a pin hole (15), with the core seal (40) and core plug (50) of the conductive core (34) being fitted in an interfering manner to an inner surface defining the pin hole (15); and at least one pin (70), comprising a pin body (75), a first crimping structure (72) crimped to the core seal (40), a second crimping structure (74) crimped to a conductive outer surface of the conductive core (34), and a stop structure preventing the pin (70) from moving in a longitudinal direction (L).