Charging Connector Locking Member for Compact Wear-Resistant Engagement

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Solution Overview

Problem

Existing connector lock mechanisms for charging connectors are prone to damage and wear, leading to potential separation of the charging connector from the inlet due to their swingable design and exposed components, which increases the height dimension and risk of wear.

Innovation Solution

A connector lock device with a retractable locking member driven by an actuator, such as a solenoid, that keeps the locking tip inside the housing during non-use and uses a cover member with a locking portion to prevent damage and excessive force, allowing for a compact design and reduced wear.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a swingable locking arm is used to engage with the inlet, then the charging connector can be locked to the inlet, but the height dimension of the charging connector increases due to the required swing space

Engineering Contradiction:

Improvelocking capabilityVSAvoidheight dimension

Core Design Contradiction:

ReliabilityVSLength of stationary object

Solution Approach 1:

Instead of using a swingable locking arm that requires significant swing space, the patent inverts the approach by using a linearly movable locking member driven by a solenoid actuator. The locking member moves forward and backward in a straight line along the longitudinal axis of the connector, eliminating the need for lateral swing space and thereby reducing the height dimension while maintaining locking capability.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent replaces the purely mechanical swingable locking arm system with an electromechanical system using a solenoid actuator. The solenoid converts electrical energy to mechanical linear motion, driving the locking member forward to engage with the inlet. This substitution eliminates the complex swing mechanism and reduces the space requirements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If the locking claw and lock operation portion are exposed outside the connector case, then the locking mechanism can be operated, but the locking arm is vulnerable to direct impact damage when the connector is dropped

Engineering Contradiction:

Improvelocking operation accessibilityVSAvoidimpact damage vulnerability

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent applies the nesting principle by placing the locking member inside the housing of the charging connector. The locking member is accommodated within the housing cavity and only its tip portion protrudes when in the locked state. This nested arrangement protects the locking mechanism from external impacts while allowing it to perform its locking function when engaged with the inlet.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The solenoid actuator automatically drives the locking member to the advanced locked position when the charging connector is inserted into the inlet. This preliminary automatic locking action eliminates the need for exposed manual operation components, as the locking occurs automatically upon insertion, reducing exposure to external damage.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If the locking arm is always biased toward the locking position by a coil spring, then the locking mechanism maintains engagement, but the locking claw repeatedly slides against the inlet surface causing wear and potential breakage

Engineering Contradiction:

Improveengagement maintenanceVSAvoidservice life of locking components

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent replaces the coil spring biasing mechanism with a solenoid actuator that provides controlled linear motion. The solenoid can precisely position the locking member and maintain engagement without continuous sliding contact. The electromagnetic force replaces the mechanical spring force, allowing for controlled engagement and disengagement that reduces wear on the locking components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces dynamic control through the solenoid actuator, which can actively adjust the position of the locking member. Unlike a passive spring-biased system that maintains constant contact, the solenoid can engage the locking member only when needed and hold it in position without repetitive sliding, thereby extending the service life of the locking components while maintaining reliable engagement.

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution prevents damage to the locking member and reduces the risk of the charging connector coming off the inlet, maintaining a compact form factor and avoiding fatal damage during forced separation.

Implementation Method 1

a locking member that is driven forward and backward by an actuator provided in a housing of the charging connector

Methodology Applied

Scientific EffectSolenoid: Solenoid

Data Source

PatentUS12620750B2Connector lock device

Publication Date: 2026.05.05 YAZAKI CORP

AI summary

A connector lock device includes: a charging connector that supplies power to a battery; an inlet to which the charging connector is fitted; and a locking member that is driven forward and backward by an actuator provided in a housing of the charging connector, and of which a tip portion is retracted into the housing at a retracted position and protrudes out of the housing at an advanced position to be locked to a locked portion of the inlet and prevent the charging connector from being separated from the inlet.