Bolted Connector Structure With Insulated Terminal Exposure Control
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Solution Overview
Problem
In charging connectors, if the safety circuit fails to function properly, there is a risk of electric shock due to the energization of power supply wires and terminals when the housing cover is open, posing a hazard to workers or external objects.
Innovation Solution
A connector design featuring a first terminal with a penetrating fastening hole, a second terminal with a corresponding fastening hole, an insulating cover portion on the second housing to shield the exposed part of the second terminal, a conductive relay portion for electrical connection, and a fastening member to secure the relay portion between the terminals, preventing contact during bolting operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the housing cover is open during bolting operation, then the bolting operation can be performed, but the worker is exposed to electric shock hazard from energized terminals
Solution Approach 1:
The housing is divided into multiple sections: a first housing containing the first terminal, a second housing containing the second terminal, and an insulating cover portion that can be selectively positioned. This segmentation allows the insulating cover to be placed only where needed (covering the second terminal during bolting) while leaving other areas accessible, thus enabling safe bolting operation without requiring the entire housing cover to be open.
Solution Approach 2:
An insulating cover portion is introduced as an intermediary element between the worker and the energized second terminal. This insulating cover acts as a protective barrier that prevents direct contact with the hazardous terminal during bolting operations, while still allowing the bolting operation to proceed normally. The insulating cover is positioned only in the specific area where hazard exists, maintaining operational accessibility elsewhere.
2Object-affected harmful factors
If the insulating cover portion covers the second terminal, then worker safety is improved, but the electrical connection between terminals is blocked
Solution Approach 1:
The insulating cover portion is segmented to cover only the specific hazardous area of the second terminal where worker contact is possible, while leaving the connection interface with the first terminal exposed and accessible. This selective coverage maintains electrical connectivity while providing protection where needed.
Solution Approach 2:
The insulating cover portion provides insulation only in the local area where hazard exists (where worker contact is possible), rather than covering the entire second terminal. The connection interface remains uncovered to maintain electrical connectivity, thus achieving local protection without affecting overall electrical function.
3Reliability
If the relay portion is disposed in the exposed part of the second housing, then electrical connection is enabled, but the second terminal remains exposed to contact
Solution Approach 1:
The insulating cover portion serves as an intermediary that allows the relay portion to be disposed in the exposed area while preventing direct contact with the second terminal. The insulating cover bridges the gap between the need for electrical connection (exposed relay portion) and the need for worker protection (covered second terminal).
Data Source
AI summary
A connector includes a first terminal formed with a penetrating first fastening hole, a first housing for holding the first terminal, a second terminal connectable to an external terminal and formed with a penetrating second fastening hole, a second housing including an insulating cover portion for covering the second terminal with a part of the second terminal on the side of the first terminal exposed, the second housing holding the second terminal, a conductive relay portion disposed in a part of the second housing where the second terminal is exposed, the relay portion electrically connecting the first terminal and the second terminal, and a fastening member for fastening the first terminal, the second terminal and the relay portion with the relay portion sandwiched between the first terminal and the second terminal.