Wire Harness Joint Connector with External Locking Tabs
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Solution Overview
Problem
Conventional wire harnesses with joint connectors have a large projection amount from the wire harness main body due to the cover housing the terminal locking tabs, which increases the size and restricts downsizing while maintaining the locking force.
Innovation Solution
A joint connector design with terminal locking tabs that deflect between locking and unlocking positions, integrated into the external wall of the connector housing, allowing the joint connector to be fixed onto the peripheral surface of the wire harness main body, reducing the thickness and projection amount, and using a tape to restrict tab displacement and maintain locking force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cover is provided to house the terminal locking tabs, then the locking force is maintained, but the projection amount of the joint connector increases
Solution Approach 1:
The patent extracts the terminal locking tabs from the enclosed cover structure and positions them on the external surface of the connector housing. This allows the locking function to be maintained while eliminating the need for a cover that would increase the projection amount, directly resolving the contradiction between maintaining locking force and reducing size.
Solution Approach 2:
The terminal locking tabs are repositioned from an internal three-dimensional enclosure to an external two-dimensional surface arrangement. By placing the tabs on the outer surface of the housing rather than inside a cover, the design maintains locking functionality while minimizing the projection amount in the depth dimension.
2Volume of stationary object
If the joint connector is downsized, then the wire harness size is reduced, but the locking force may be compromised
Solution Approach 1:
By extracting the locking tabs from the cover structure and placing them directly on the housing exterior, the design eliminates the space-consuming cover while preserving the locking mechanism, thus downsizing the connector without compromising locking force.
Solution Approach 2:
The locking function is merged directly into the housing structure itself rather than being a separate component within a cover. The terminal locking tabs are integrally formed with or directly mounted on the housing, combining the housing and locking mechanism into a unified compact structure.
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 design minimizes the size of the wire harness by reducing the joint connector's thickness and projection from the main body while maintaining the locking force, allowing for easier storage and secure fixation, preventing disengagement and damage.
Implementation Method 1
Each of the terminal locking tabs is configured to deflect between a locking position that locks each of the wire terminals and an unlocking position that unlocks each of the wire terminals
Data Source
AI summary
A wire harness has a joint connector having a joint terminal and a connector housing. The joint terminal has a short-circuit section and a plurality of electrical contact portions aligned in a direction substantially orthogonal to an axial direction of wires. The connector housing has an external wall surrounding terminal chambers and exposed to the outside; and a plurality of terminal locking tabs formed integrally with the external wall the terminal locking tabs locking wire terminals. Each of the terminal locking tabs has a shape deflectable between an engaging position that locks each wire terminal and a disengaging position. The joint connector is fixed to the peripheral surface of a wire harness main body while the outer surface of the external wall of the connector housing faces and contacts the peripheral surface of the wire harness main body the connector housing being provided with the terminal locking tabs.