Charging Connector Emergency Release Mechanism
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Solution Overview
Problem
Existing charging connectors with emergency withdrawal mechanisms often result in the loss of components such as covers and caps during emergency withdrawal and return operations due to their design requirements.
Innovation Solution
A charging connector design that includes a lock lever, a release-disabling portion, and a cap that can be moved between accommodated and pulled-out positions, allowing for emergency withdrawal without detaching the cover or cap, and a return operation that repositions the cap to restore the original configuration, preventing component loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the cover and cap are detached from the shell during emergency withdrawal and return operations, then the release jig can be inserted to unlock the lock lever, but the detached cover and cap may be lost
Solution Approach 1:
The cap is designed to be movable between a first position (covering the insertion hole) and a second position (pulled out to expose the insertion hole). This dynamic positioning allows the cap to serve dual functions: protecting the insertion hole during normal operation and exposing it during emergency withdrawal when pulled out to engage with the release jig
Solution Approach 2:
The cap serves multiple functions: (1) covering and protecting the insertion hole during normal operation, (2) being pulled out to expose the insertion hole for release jig insertion during emergency withdrawal, and (3) being engaged by the return jig to facilitate the return operation. This multi-functionality eliminates the need for separate protective covers
2Ease of operation
If the cap is pulled out to expose the insertion hole for release jig insertion, then emergency withdrawal can be performed, but the cap may be detached and lost
Solution Approach 1:
The engagement protrusion on the cap and the corresponding engagement groove on the shell form an intermediary mechanical connection that allows the cap to be pulled out for emergency withdrawal while preventing complete detachment. This intermediary structure serves as a controlled interface between the cap and shell
Solution Approach 2:
The cap transitions from a fixed covered state to a pulled-out exposed state during emergency withdrawal, with the engagement protrusion-groove mechanism dynamically controlling the extent of movement. The cap can be pulled out sufficiently to expose the insertion hole but is mechanically constrained from being completely detached
3Reliability
If the cap structure is made more complex with engagement protrusions and grooves, then the cap can be securely retained during emergency withdrawal, but the device complexity increases
Solution Approach 1:
The retention mechanism is segmented into discrete, simple elements: an engagement protrusion on the cap and a corresponding engagement groove on the shell. This segmentation allows for easy manufacturing and assembly while providing reliable retention functionality
Solution Approach 2:
The engagement protrusion and groove are localized features positioned specifically at the interface between the cap and shell where retention is needed. The rest of the cap and shell structures remain simple and unadorned, maintaining overall structural simplicity while providing localized retention functionality
Data Source
Figure 1~2
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Figure 5~6
AI summary
A charging connector comprises a lock portion, a cap and a release-disabling portion. When the cap is located at an accommodated position and is located at a first rotation position, the release-disabling portion is located at a disabling position, and a release jig is not insertable. When the cap is located at a pulled-out position and is located at the first rotation position, the release-disabling portion is movable to an allowing position, and the release jig is allowed to be inserted so that the lock portion is moved to an unlock position. When the cap is located at the pulled-out position and is located at a second rotation position, the cap is movable to the accommodated position. When the cap located at the accommodated position is moved to the first rotation position, the cap lifts up the release-disabling portion, and the release-disabling portion is moved to the disabling position.