Wire Connection Module Tail Cap Structure for Stable Plug Assembly
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Solution Overview
Problem
Existing wire connection modules in plug connectors are prone to displacement and detachment during assembly due to the short and small enclosed portion of the inner member, leading to failed connections, especially in high-data transmission applications within vehicles.
Innovation Solution
A wire connection module design featuring an outer member with a receiving groove, an insulated member with positioning portions, and a tail cap that encloses a large portion of the insulated member, along with combining portions and positioning portions to limit axial rotation and provide a mistake-proofing function, ensuring the insulated member remains securely positioned within the outer member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the inner member is enclosed by a short and small portion of the contact portion, then the assembly structure is simple, but the inner member is prone to displacement and detachment during assembly
Solution Approach 1:
The patent applies nesting by placing the insulated member inside the outer member, with the tail cap enclosing a large portion of the insulated member's outer surface. This nested structure provides secure containment while maintaining assembly simplicity, resolving the contradiction between simple structure and connection stability.
Solution Approach 2:
The patent introduces positioning portions that extend in the axial direction to limit axial rotation, adding a dimensional constraint that prevents displacement and detachment. This dimensional enhancement maintains structural simplicity while significantly improving connection reliability.
2Productivity
If the insulated member is not securely positioned, then the assembly process is fast, but the connection stability is poor
Solution Approach 1:
The patent incorporates positioning portions and combining portions that are pre-formed on the insulated member and outer member respectively. These features are built-in during manufacturing, enabling quick and reliable assembly without requiring additional securing steps, thus maintaining high assembly speed while ensuring connection stability.
Solution Approach 2:
The positioning portions and combining portions enable the components to self-align and self-secure during assembly. The groove and protrusion structures automatically engage to limit axial rotation and secure the insulated member, eliminating the need for complex external fastening mechanisms and maintaining fast assembly pace.
3Reliability
If the outer member encloses a large portion of the insulated member, then the connection stability is improved, but the device complexity increases
Solution Approach 1:
The outer member encloses a large portion of the insulated member through a nested configuration where the tail cap of the outer member surrounds the body of the insulated member. This nesting provides robust connection stability while using simple geometric forms that avoid excessive structural complexity.
Solution Approach 2:
The patent applies local quality by providing enclosure and positioning only where needed - the tail cap encloses the insulated member's outer surface, and positioning portions are placed at specific locations to limit axial rotation. This targeted approach improves connection stability without adding unnecessary complexity throughout the entire structure.
Data Source
AI summary
A wire connection module and a plug connector are provided. The plug connector includes a housing and a plurality of wire connection modules. The housing has a plurality of receiving spaces, and the housing has a plurality of first mating surfaces respectively at inner sides of the receiving spaces. The wire connection modules are respectively in the receiving spaces. The wire connection module includes an outer member, an insulated member, and a tail cap. The outer member has a receiving groove, one of two ends of the outer member has a mating side, the other end of the outer member has an assembling side, the insulated member is in the receiving groove, and the tail cap is mated with the assembling side and assembled outside an outer portion of the outer member. An outer portion of the tail cap is positioned at the first mating surface.