Wire Lead-Out Connector Housing for Bend Radius Protection
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Solution Overview
Problem
Conventional connectors for flexible conductors in smart clothes face issues with high electric resistance and increased cost due to the need for multiple components, and are prone to conductor breakage under tensile forces.
Innovation Solution
A connector design with a housing that accommodates the electric wire and connection object, featuring a lead-out port with multiple contact points to disperse load and maintain a minimum bending radius, eliminating the need for additional bendable bushing members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bendable bushing member is added to protect the electric wire, then the reliability of the connector is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the wire protection function into the existing connector housing by forming a guide portion that extends from the housing. This integration eliminates the need for a separate bendable bushing member while maintaining the protective function against conductor breakage during bending operations.
Solution Approach 2:
The guide portion formed by the housing acts as an intermediary structure between the conductor and the external environment. It provides a controlled bending path and protects the conductor from direct mechanical stress, serving the same protective purpose as a separate bushing member would.
2Ease of operation
If the electric wire is led out from the housing, then the ease of operation is improved, but the conductor portion may break under tensile forces
Solution Approach 1:
The guide portion is pre-formed as an integral part of the housing structure, creating a predetermined bending path for the electric wire before the wire is actually installed. This preliminary structural preparation ensures that the wire will naturally follow a protected path that maintains minimum bending radius and reduces stress concentration points.
Data Source
AI summary
A connector includes a housing accommodating an end of the connection object and an end of the electric wire, the connection object and the conductor portion of the electric wire making contact with and being electrically connected to each other in the housing, the housing having an electric wire lead-out port leading out the electric wire from inside to outside of the housing, the electric wire lead-out port having a first contact portion and a second contact portion that make contact with the electric wire at two positions separate away from each other along a length direction of the electric wire so as to disperse a load applied to the electric wire when the electric wire is led out from the housing at a predetermined minimum bending radius determined by a shape of the housing around the electric wire lead-out port.