Connector Abutment Member Simplifies Terminal Fixation
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Solution Overview
Problem
The existing feeder connector for electric vehicles and hybrid vehicles has a complex configuration due to multiple parts, including a rear holder, which increases assembly time and difficulty, and makes disassembly challenging during maintenance or repair.
Innovation Solution
The connector design incorporates an abutment member with an insertion slit, reducing the number of parts and simplifying the configuration by allowing the connector housing to be opened without a rear holder, facilitating easy assembly and disassembly by guiding electric wires through the slit for correct positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rear holder is used to fix the terminal and fixing members in the connector housing, then the terminal is securely held, but the number of parts increases and assembly complexity increases
Solution Approach 1:
The abutment member integrates the functions of the rear holder and the fixing member retention mechanism into a single component. The abutment member has an abutment portion that contacts the fixing member and an insertion slit for receiving the terminal, eliminating the need for a separate rear holder while maintaining secure fixation of all components
2Reliability
If a rear holder is fitted to the rear end of the connector housing, then the terminal is fixed, but assembly time increases due to complex construction
Solution Approach 1:
The abutment member combines multiple functions into one component: it abuts on the fixing member to prevent its movement, provides an insertion slit for terminal placement, and serves as a structural support element. This integration reduces the number of assembly steps and eliminates the need to fit a separate rear holder, significantly reducing assembly time
3Reliability
If a rear holder is fitted to close the rear end of the connector housing, then the internal components are secured, but disassembly time increases and maintenance becomes difficult
Solution Approach 1:
The abutment member is designed as a separate, removable component from the connector housing. It can be easily detached from the rear end of the housing, allowing quick access to the terminal and fixing member for maintenance or repair. This segmentation enables easy disassembly while still providing secure component retention during operation
4Reliability
If the connector housing is assembled with caution to avoid wrong direction assembly, then proper connection is ensured, but assembly time increases
Solution Approach 1:
The abutment member and insertion slit are designed with asymmetric features that provide built-in positioning guidance. The insertion slit is positioned at a specific location on the abutment member, and the overall configuration creates a unique assembly orientation. This asymmetric design allows workers to assemble the connector housing in the correct direction without requiring excessive caution or complex alignment procedures, reducing assembly time while ensuring proper connection
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
The connector (1) to be mated with a mating connector has a connector housing (3) receiving a terminal (24) and fixing members (29, 33) for fixing the terminal, (24) a case (2) receiving the connector housing (3), and an abutment member (41) vertically arranged in the case (2) so that the abutment member (41) is positioned at the end portion (3a) of the connector housing (3) away from the mating connector, and abutting on the fixing member (33) received in the end portion (3a) of the connector housing (3) so as to prevent the terminal (24) from moving in a longitudinal direction of the terminal. Thus, the connector (1) can reduce the number of parts and simplify structure thereof. Furthermore, the connector can be assembled and disassembled at short time.