Device Connector Bolt Cap Mounting Recess Design
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Solution Overview
Problem
Existing device connector systems require additional parts to securely hold a bolt cap, leading to increased complexity and part count, as the bolt cap and terminal fitting interact during tightening, causing rotation issues.
Innovation Solution
A device connector design featuring a connector main body with an insertion hole and a bolt cap that uses a mounting recess between the seat and bolt flange to securely hold the bolt cap without additional parts, utilizing a flexible hinge for attachment and a C-ring for rotational support, along with a conductive shield shell for sealing and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mounting recess is formed separately from the stud bolt and bolt cap, then the bolt cap can be securely held, but the number of parts increases
Solution Approach 1:
The mounting recess is integrated into the terminal fitting structure rather than being a separate component. The recess is formed directly in the terminal fitting body, combining the mounting function with the existing terminal fitting part, thus securing the bolt cap without increasing the number of parts.
Solution Approach 2:
The terminal fitting serves multiple functions: it provides electrical connection, structural support, and includes the mounting recess for securing the bolt cap. By making the terminal fitting multi-functional, the patent eliminates the need for separate mounting components while maintaining secure bolt cap holding.
2Reliability
If the bolt cap and terminal fitting come into contact in a turning direction, then rotation of the bolt cap is prevented, but the structure becomes more complex
Solution Approach 1:
The mounting recess and corresponding protrusion on the bolt cap are designed with asymmetric geometries that engage in a specific turning direction. This asymmetric design prevents rotation of the bolt cap while maintaining a relatively simple overall structure, as the anti-rotation function is achieved through the shape of the engaging features rather than additional components.
3Reliability
If additional parts are used to hold the bolt cap, then the bolt cap can be securely mounted, but manufacturing complexity increases
Solution Approach 1:
The mounting recess is formed as an integral part of the terminal fitting through molding or machining operations already required for the terminal fitting itself. This integration eliminates the need for separate manufacturing processes for additional mounting parts, thereby reducing overall manufacturing complexity while ensuring secure bolt cap mounting.
Data Source
AI summary
A male connector (10) is mounted to a case (C) of a device and includes a bolt (B) with a tightening portion (B1) to be engaged by a tool for screwing the bolt into a bolt hole (C2). A shield (20) includes an insertion hole (22) for receiving the bolt (B) and a bolt cap (40) covers the tightening portion (B1). A seat (21) is provided adjacent the insertion hole (22) and is sandwiched by an edge of the bolt hole (C2) and the tightening portion (B1) in the axial direction. A flange (B12) projects out from the tightening portion (B1). A mounting recess (D) is formed between the flange (B12) and the seat (21). A mounting portion (42) is mounted in the mounting recess (D) and engages the bolt cap (40) to hold the bolt cap (40) on the tightening portion (B1).