Vehicle Wire Connector Layout Without Rear Bend Space
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Solution Overview
Problem
Conventional connectors for electric vehicles require additional space for bending electric wires and increased size due to wire diversion, which complicates installation and increases the overall dimensions.
Innovation Solution
The connector design includes a housing with terminals and insulating members, where electric wires are drawn out straight from the housing openings, eliminating the need for rear space and using a crimped round terminal and intermediate bus bar to connect wires directly to terminals, reducing the connector's size and installation area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electric wires are drawn out from the rear surface of the housing and bent, then the connector can be assembled, but additional space is required at the rear of the connector for bending the wires
Solution Approach 1:
The patent changes the wire exit direction from the rear surface to the side surface of the housing, utilizing a different spatial dimension. The side surface opening allows wires to be drawn out laterally rather than requiring rear space for bending, thus resolving the contradiction between ease of wire assembly and rear space requirement.
2Reliability
If rubber stoppers are mounted on electric wires for waterproofing, then sealing performance is improved, but a further large space is required at the rear of the connector
Solution Approach 1:
By moving the wire exit to the side surface of the housing, the patent eliminates the need for rear space accommodation of rubber stoppers. The lateral exit configuration allows waterproofing components to be positioned along the side opening rather than requiring extended rear space, maintaining sealing performance while reducing rear area occupation.
3Device complexity
If electric wires are diverted to avoid interference and then aligned in the same direction, then wire organization is improved, but the connector size increases in the lateral direction
Solution Approach 1:
The patent extracts the wire alignment and organization function from the rear space configuration and relocates it to the side surface opening. By having wires exit laterally, the need for complex diversion and realignment maneuvers is eliminated, as wires can be directly routed from their respective terminals to the side opening without interfering with each other, thus reducing connector width while maintaining wire organization.
Data Source
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AI summary
A connector with electric wires includes a housing mounted to a vehicle body, two terminals housed in the housing, and two electric wires each connected to the terminal. The two electric wires are drawn out from openings of the housing with the two electric wires disposed in a longitudinal direction (arrow Y direction) and extended straight in a direction (arrow X direction) orthogonal to the longitudinal direction of the terminal. Inside the housing, the two terminals and the two electric wires are arranged on the same plane.