Bolted Device Connector Housing for Reliable Terminal Connection
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Solution Overview
Problem
Existing device connectors for supplying power to devices in metal cases, such as those in electric vehicles, face challenges in achieving reliable connections between terminals, leading to a demand for improved connection reliability.
Innovation Solution
A device connector design featuring a first housing with bolt insertion holes and a second housing with corresponding bolt insertion holes, along with shielding shells for secure fixation, allows for strong connections between terminals and device-side terminals through bolt tightening, enhancing connection reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the first and second terminals are connected only through resilient contact pieces in the rectangular tube portions, then the connector structure is simple and easy to assemble, but the connection reliability is insufficient
Solution Approach 1:
The patent combines two connection methods: resilient contact pieces for initial connection and bolt tightening for strong mechanical bonding. The bolt insertion holes are formed in both the first terminal and second terminal, allowing bolts to pass through and secure the connection, while the resilient contact pieces provide additional contact pressure and electrical connection stability.
Solution Approach 2:
The resilient contact pieces are pre-installed in the rectangular tube portions of the second terminals before the housing connection. When the housings are connected, the projecting ends of the first terminals automatically enter the rectangular tube portions and come into contact with the resilient contact pieces, establishing preliminary electrical connection before bolt tightening is applied.
2Ease of operation
If bolts are inserted through the housing to tighten the terminals, then strong mechanical connection is achieved, but the operation becomes difficult due to limited access space
Solution Approach 1:
The housing is divided into two separate housings (first housing and second housing) that can be connected together. The fitting portion of the first housing projects outwardly from the case, providing accessible space for bolt tightening operations. This segmentation allows the operation hole to be positioned in a location that is easily accessible from the outside, while still maintaining strong internal connections.
Solution Approach 2:
The fitting portion acting as an intermediary structure that projects outwardly from the case creates an accessible operation space. This intermediary structure allows bolt tightening operations to be performed from the outside without requiring disassembly of the housing or complex internal access mechanisms.
3Reliability
If the bolt insertion holes are positioned for strong terminal connection, then connection reliability improves, but the holes may be difficult to access for tightening operations
Solution Approach 1:
The fitting portion of the first housing projects outwardly from the case in a direction that provides both structural support for strong terminal connections and dimensional access for bolt tightening operations. The operation hole is formed in this fitting portion, positioned to be accessible from the outside while maintaining proper alignment with the bolt insertion holes in the terminals for reliable connection.
Data Source
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AI summary
An object of the present invention is to provide a device connector capable of improving connection reliability. A device connector to be connected with device-side terminals accommodated in a metal case C is provided with a first housing 10 for holding first terminals 20 connectable with the device-side terminals by bolt tightening and a second housing 50 connectable with the first housing 10 and adapted to hold second terminals 60 fixed to ends of wires 61. Connecting portions 21, 63 of the first and second terminals 20, 60 are arranged one over the other in a fitting portion 11 to the second housing 50 and are respectively formed with bolt insertion holes 21 A, 63A. The fitting portion 11 is formed with an operation hole 23 used for bolt tightening operations for the connecting portions 21, 63.