EV Charging Connector Threaded Locking Against Vibration Loosening
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Solution Overview
Problem
Conventional charging connectors for electric vehicles are prone to loosening due to vibrations during the charging process, which can lead to unstable connections and potential safety issues.
Innovation Solution
The charging connector incorporates a movable shell with a threaded guiding groove, a stopper that moves between locking and unlocking positions, and flexible bridges with guiding blocks, which work together to securely engage with the charging base and prevent loosening due to vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the charging connector uses a friction-based locking mechanism, then the structure is simple, but the connection becomes loose during vibration
Solution Approach 1:
The patent transforms the static friction-based locking mechanism into a dynamic threaded locking system. The movable shell with threaded guiding groove converts rotational motion into linear motion, creating a progressive self-tightening effect that actively counteracts vibration-induced loosening forces.
Solution Approach 2:
The patent introduces a stopper as an intermediary component between the movable shell and the charging base. The stopper engages with the threaded guiding groove to translate rotational movement into axial locking force, mediating the interaction between the connector and charging base to prevent loosening.
2Reliability
If the charging connector uses a threaded guiding groove mechanism, then the anti-loosening performance is improved, but the device complexity increases
Solution Approach 1:
The patent merges multiple functions into the movable shell: it serves as both the locking element (through the threaded guiding groove) and the positioning element (through the stopper interaction). This integration reduces the need for separate components, mitigating the complexity increase despite the enhanced anti-loosening capability.
Solution Approach 2:
The patent segments the locking function into distinct components: the threaded guiding groove for progressive engagement, the stopper for positioning and force transmission, and the flexible bridges for guiding. This segmentation allows each component to be optimized for its specific function while working together as a cohesive system.
3Manufacturing precision
If the charging connector uses flexible bridges with guiding blocks, then the engagement precision is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent employs flexible bridges as thin-walled structures that can elastically deform to accommodate manufacturing tolerances. The flexibility of these bridges allows the guiding blocks to self-align during assembly, achieving precise engagement without requiring extremely tight manufacturing tolerances.
Solution Approach 2:
The flexible bridges act as cushioning elements that absorb misalignment and positioning errors before they affect the final engagement precision. The elastic deformation of the bridges compensates for manufacturing variations, ensuring accurate engagement of the guiding blocks with the charging base.
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
This design effectively prevents the charging connector from loosening during vibrations, ensuring a stable and secure connection throughout the charging process, thereby enhancing safety and reliability.
Implementation Method 1
The movable shell has a threaded guiding groove formed at a front of an inner surface of the movable shell. The threaded guiding groove is engaged with the protrusion of the charging base.
Implementation Method 2
the locking section is fastened to the charging base by a friction force between the charging base and the charging section
Implementation Method 3
Two portions of an outer peripheral surface of the housing protrude outward to form two flexible bridges. An outer surface of each flexible bridge protrudes outward to form a guiding block.
Data Source
AI summary
A charging connector includes a housing, at least one terminal, a movable shell and a stopper. A middle of the housing has an internal insulator fixed in the housing. The at least one terminal is disposed in the internal insulator. The movable shell is rotatably disposed around an outer periphery of the housing, and the movable shell has a threaded guiding groove. The stopper is movably mounted around the housing. The stopper is moved between an unlocking position and a locking position. When the stopper is moved frontward to the locking position, the stopper is interfered with the movable shell to stop the movable shell from rotating.