Integrated Charging Terminal Bracket to Prevent Loosening
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Solution Overview
Problem
Existing charging systems for new energy vehicles face difficulties in assembly, high production costs, and terminal instability due to mounting gaps, leading to system failure from repeated use.
Innovation Solution
A bracket integrated with a terminal, formed through integral injection molding with an anti-rotation portion, simplifies assembly, reduces parts, and enhances stability by preventing axial or radial movement, thus improving durability and reducing labor costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If terminals are manually fixed on a bracket using clamping, then the terminal can be mounted on the bracket, but the assembly process becomes difficult and labor-intensive, resulting in low yield and high production cost
Solution Approach 1:
The terminal and bracket are merged into a single integrated component through integral injection molding. The terminal is formed as an integral part of the bracket, eliminating the need for separate assembly operations. This combining of previously separate components resolves the technical contradiction by making the manufacturing process easier while simultaneously improving productivity through reduced assembly steps and lower labor requirements
2Ease of manufacture
If terminals are manually fixed on a bracket using clamping, then the terminal can be mounted on the bracket, but the number of parts increases, resulting in high production cost
Solution Approach 1:
The terminal and bracket are merged into a single integrated component through integral injection molding. This eliminates the need for separate clamping parts, fasteners, and mounting hardware. By combining multiple parts into one, the invention reduces device complexity and the total number of components, thereby lowering production costs while maintaining ease of manufacture
3Ease of manufacture
If terminals are clamped on a bracket, then the terminal can be mounted on the bracket, but mounting gaps are created, causing the terminal to shake and move after repeated use, eventually leading to system failure
Solution Approach 1:
The terminal and bracket are merged into a single integral component, eliminating mounting gaps that would otherwise allow shaking and movement. The integral structure ensures the terminal is firmly attached with no clearance for motion, preventing the reliability issues associated with repeated plugging and unplugging operations
Solution Approach 2:
An anti-rotation portion with a groove structure is designed on the terminal to prevent rotational movement. This curved groove feature works in conjunction with the integral molding to completely eliminate all degrees of freedom for terminal movement, ensuring both axial and radial stability while maintaining the firm attachment benefit of integral construction
Data Source
AI summary
Provided are a bracket integrated with a terminal, and a charging device. The bracket integrated with the terminal includes a bracket and at least one terminal, where an anti-rotation portion is disposed on the terminal and includes a first groove and/or a protrusion disposed on a side surface of the terminal, and the bracket is formed on at least part of the anti-rotation portion in an integral injection molding manner. According to the bracket integrated with the terminal provided by the present disclosure, the terminal and the bracket are integrally formed in an integral injection molding manner, such that a process of manually plugging the terminal into the bracket is omitted, and not only the yield can be improved, but also the costs can be reduced.