Fastener-Based Connector Assembly for Compact Right-Angle Terminals
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connectors at the battery pack end require large installation spaces due to non-disassemblable 90-degree bent metal bars, hinder miniaturization, and lack functions like waterproof sealing, electromagnetic shielding, and finger protection.
Innovation Solution
A fastener with an outer flange and screw rod for vertical fastening, a conductive sleeve, and a threaded connection with a bolt, integrated into a connector design that includes an outer shielding shell and insulation inner housing, providing electrical connections with waterproof sealing and finger protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a 90-degree bent metal bar is used for right angle electrical connections, then the electrical connection function is achieved, but the connector size becomes too large and cannot be miniaturized
Solution Approach 1:
The bent metal bar is divided into separate straight segments connected by a fastening mechanism. The conductive terminal and mating terminal are both straight bars that can be independently positioned and connected through the fastener assembly, eliminating the need for a single-piece bent structure and enabling compact connector design.
Solution Approach 2:
The fastener assembly with the conductive sleeve is inserted into the insulation inner housing, which is then placed within the outer shielding shell. This nested arrangement integrates multiple functions (electrical connection, insulation, shielding, sealing) into a compact structure, achieving miniaturization while maintaining all required functions.
2Reliability
If a single-piece bent metal bar is used, then the electrical connection is secure, but the connector cannot be disassembled and assembled, requiring large installation space
Solution Approach 1:
The electrical connection path is segmented into modular components (conductive terminal, conductive sleeve, mating terminal) that can be independently assembled and disassembled. The fastener assembly provides a reliable electrical connection while allowing the connector to be taken apart and reassembled, combining reliability with serviceability.
Solution Approach 2:
The fastening function and electrical connection function are merged into a single fastener assembly. The screw rod simultaneously secures the conductive sleeve and establishes electrical contact through the conductive terminal, achieving both mechanical fastening and electrical connection with a unified structure.
3Adaptability or versatility
If traditional connector design is used, then basic electrical connection is achieved, but multiple functions (waterproof sealing, electromagnetic shielding, high-voltage interlocking, finger protection) cannot be simultaneously possessed
Solution Approach 1:
Each component is designed to perform multiple functions: the conductive sleeve provides both electrical connection and high-voltage interlocking; the insulation inner housing provides insulation, finger protection, and supports waterproof sealing; the outer shielding shell provides electromagnetic shielding and structural protection. This multi-functional design achieves versatility without significantly increasing size.
Solution Approach 2:
The nested structure allows multiple functional layers to be integrated: the conductive sleeve (electrical connection + high-voltage interlocking) is nested within the insulation inner housing (insulation + finger protection), which is nested within the outer shielding shell (electromagnetic shielding). This nested arrangement enables multiple functions to coexist in a compact configuration.
Data Source
AI summary
A fastener includes an outer flange, a threaded hole located at a first end of the fastener, and a screw rod located at a second end of the fastener. The screw rod of the fastener is adapted to pass through a conductive sleeve and be threaded with a conductive terminal. The outer flange of the fastener is adapted to axially rest on one end of the conductive sleeve such that the fastener can vertically fasten the conductive sleeve to the conductive terminal. The threaded hole of the fastener is adapted to form a threaded connection with a bolt such that a mating terminal can be fastened to one end of the conductive sleeve through the bolt.