Compact Shielded Connector Structure for Sealing and HV Interlock
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Solution Overview
Problem
Existing high-voltage bolt connectors in new energy vehicles face challenges with complex structure, large volume, and difficulties in achieving waterproof sealing, electromagnetic shielding, high-voltage interlocking, and finger protection.
Innovation Solution
A connector design comprising an outer shielding shell, inner insulation housing, electric transmission component, conductive terminal, insulation retaining body, and fastening assembly, which includes features like insulation sleeves, sealing rings, and elastic buckles to ensure waterproof sealing, electromagnetic shielding, and finger protection while minimizing size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connector designs are used, then waterproof sealing and electromagnetic shielding can be achieved, but the structure becomes complex and volume increases
Solution Approach 1:
The patent combines multiple protective functions (waterproof sealing, electromagnetic shielding, high-voltage interlocking, and finger protection) into a single integrated connector structure. The outer shielding shell integrates the electromagnetic shielding function while the inner insulation housing provides waterproof sealing, both within one unified connector body, eliminating the need for separate protective components.
Solution Approach 2:
The connector design achieves multi-functionality where a single structure simultaneously provides waterproof sealing through the inner insulation housing, electromagnetic shielding through the outer shielding shell, high-voltage interlocking via the conductive terminal with insulation retaining body, and finger protection through the integrated housing design, all within one connector unit.
2Reliability
If traditional connector designs are used, then waterproof sealing and electromagnetic shielding can be achieved, but the volume becomes large
Solution Approach 1:
The patent employs a nested structure where the inner insulation housing is inserted into the outer shielding shell, and the electric transmission component is inserted into the insertion cavity of the inner housing. This nested arrangement allows multiple functional layers to occupy overlapping spatial volumes, significantly reducing the overall connector volume while maintaining all required shielding and sealing functions.
3Reliability
If multiple protective functions are integrated, then finger protection and high-voltage interlocking are achieved, but the structure becomes complex
Solution Approach 1:
The connector merges finger protection and high-voltage interlocking functions into the same structural framework. The conductive terminal with insulation retaining body provides high-voltage interlocking, while the integrated inner insulation housing and outer shielding shell structure simultaneously provides finger protection, eliminating the need for separate protective components.
4Volume of stationary object
If compact design is implemented, then volume is reduced, but achieving all protective functions simultaneously becomes difficult
Solution Approach 1:
The nested doll principle is applied by inserting the inner insulation housing into the outer shielding shell, and the electric transmission component into the inner housing's insertion cavity. This nested arrangement allows multiple functional layers to occupy overlapping spatial volumes, reducing overall connector volume while maintaining all required protective functions including waterproof sealing, electromagnetic shielding, high-voltage interlocking, and finger protection.
Solution Approach 2:
The patent utilizes vertical stacking and layered arrangement of functional components along the height direction, with the outer shielding shell providing electromagnetic shielding, the inner insulation housing providing waterproof sealing, and the conductive terminal assembly providing high-voltage interlocking. This vertical dimensionality allows all protective functions to be integrated in a compact volume.
Data Source
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AI summary
The present invention discloses a connector. The connector comprises: an outer shielding shell (1) which comprises front and rear ports (101) opposite in its longitudinal direction (Y), and a top wall and a bottom opening (102) opposite in its height direction (Z), and an installation port (103) formed in the top wall; an inner insulation housing (2) which is inserted into the outer shielding shell (1) from the rear port (101) of the outer shielding shell (1) and has an insertion cavity (201) communicated with the rear port (101), the bottom opening (102), and the installation port (103) of the outer shielding shell (1); an electric transmission component (3) which is inserted into the insertion cavity (201) of the inner insulation housing (2) and led out from the rear port (101) of the outer shielding shell (1); a conductive terminal (4) which is welded to the front end (3a) of the electric transmission component (3) inserted into the insertion cavity (201) for electrical contact with a mating terminal of a mating connector; an insulation retaining body (5) which is installed in the bottom opening (102) of the outer shielding shell (1) for retaining and positioning the conductive terminal (4); and a fastening assembly (6) which enters the inner insulation housing (2) through the installation port (103) in the top wall of the outer shielding shell (1), for fastening the conductive terminal (4) to the mating terminal. In the present invention, the structure of the connector is simple and the volume is small, which can achieve miniaturization of the connector, and can simultaneously achieve functions such as waterproof sealing, electromagnetic shielding, high-voltage interlocking, and finger protection.