Charging Inlet Rear Holder Structure for Terminal Alignment
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Solution Overview
Problem
Existing connectors with divided holders for supporting electric wires generate gaps that cause shaking of terminals when external forces are applied, affecting terminal alignment and fitting workability.
Innovation Solution
A connector design featuring an inner and outer rear holder with semicircular support surfaces and locking mechanisms that securely sandwich electric wires, preventing shaking and maintaining terminal alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the holder is divided into first holder and second holder for assembly, then the assembly process is simplified, but gaps are generated between electric wires and holder causing terminal shaking
Solution Approach 1:
The holder is divided into a first holder that supports the electric wires and a second holder that is assembled to the housing, with the first holder inserted into the second holder. This segmentation allows simplified assembly while maintaining structural integrity through the nested configuration and locking mechanism.
Solution Approach 2:
The first holder is inserted into the second holder, creating a nested structure where the locking portion of the first holder engages with the locked portion of the second holder. This nesting eliminates gaps between the electric wires and holder while maintaining assembly simplicity.
2Ease of operation
If gaps are generated between electric wires and holder, then assembly is easier, but terminal alignment is affected due to shaking
Solution Approach 1:
The first holder is pre-assembled with the electric wires and terminals before being inserted into the second holder. The locking mechanism is designed to secure the first holder in a predetermined position, ensuring proper terminal alignment is maintained during the final assembly step.
Solution Approach 2:
The first holder acts as an intermediary component between the electric wires and the second holder. It provides a stable mounting structure that prevents shaking and maintains terminal alignment, while the locking mechanism ensures secure connection to the second holder.
3Reliability
If a locking mechanism is added to secure the holders, then terminal shaking is prevented, but device complexity increases
Solution Approach 1:
The locking function is extracted as a separate mechanism consisting of a locking portion on the first holder and a locked portion on the second holder. This modular locking design secures the holders together to prevent terminal shaking while keeping the overall structure relatively simple and manageable.
Data Source
AI summary
A charging inlet includes a rear holder installed to a housing and supporting electric wires connected to the terminals accommodated in the terminal accommodating chambers. The rear holder includes an inner rear holder and an outer rear holder. In an outer peripheral portion of the inner rear holder, a plurality of outer electric wire insertion portions each having an inner electric wire support surface is provided. In an inner peripheral portion of the outer rear holder, a plurality of inner electric wire insertion portions each having an outer electric wire support surface. The plurality of inner electric wire insertion portions communicates with an outer peripheral side of the outer rear holder through a communication portion. The electric wires are sandwiched between the inner electric wire support surfaces and the outer electric wire support surfaces.