Connector Cap Recessed Portion Resolves Insertion Interference
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Solution Overview
Problem
Existing vehicle-side connectors for electric and plug-in hybrid vehicles face issues with incomplete cap insertion and reduced operability due to chamfered portions interfering with the cap's mounting process, which can lead to strength reduction and damage over time.
Innovation Solution
A connector design featuring a cap with a tubular portion and contact portion that fits into the connector housing's cavity, along with a recessed portion on the cap body to prevent interference and improve assembly workability, utilizing positioning ribs for secure fitting and a fall prevention strap to prevent cap detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a chamfered portion is formed at the inner corner portion between the lid portion and insertion portion, then the strength and durability of the cover member are improved, but the chamfered portion interferes with the opening end portion of the terminal accommodating portion, causing incomplete insertion and deteriorated operability
Solution Approach 1:
The cap is divided into three functional zones: the lid portion for covering, the insertion portion for fitting, and the recessed portion serving as a transition zone. By segmenting the structure and creating a dedicated recessed portion, the chamfered portion is isolated from the interference zone, allowing both strength and ease of operation to be optimized independently.
Solution Approach 2:
The recessed portion acts as an intermediary element between the lid portion and insertion portion. It provides a transitional space that prevents direct contact between the chamfered portion and the opening end portion, thereby mediating the conflict between structural strength and insertion operability.
2Ease of operation
If the chamfered portion is removed or repositioned to avoid interference, then the operability and insertion completeness are improved, but the strength of the cap structure is reduced
Solution Approach 1:
The cap structure is segmented into distinct functional zones with the recessed portion creating a clear separation between the strength-providing chamfered portion and the insertion-critical opening end portion. This segmentation allows each zone to optimize its function without compromising the other.
Solution Approach 2:
The recessed portion introduces a dimensional change by creating a recessed space rather than a protruding chamfered portion. This dimensional modification allows the chamfered portion to maintain structural strength while being positioned in a different spatial zone that does not interfere with insertion operability.
3Ease of manufacture
If the cap is designed with simple geometry without recessed portions, then the manufacturing complexity is reduced, but the cap cannot prevent incomplete insertion and has poor assembling workability
Solution Approach 1:
The recessed portion is pre-formed during the molding process to create a built-in guide feature. This preliminary action ensures that the cap automatically aligns and inserts completely without requiring additional adjustment or complex assembly procedures, thereby maintaining manufacturing simplicity while improving assembly precision.
Solution Approach 2:
The recessed portion creates a self-aligning mechanism where the cap's own structure guides its insertion. The recessed portion acts as a self-service feature that automatically ensures complete insertion and proper positioning, eliminating the need for external guidance mechanisms or complex assembly procedures.
Data Source
AI summary
A connector includes a connector housing and a cap. The connector housing has a terminal accommodating portion formed with a bottomed tubular cavity. The cap has a cap body configured to cover an opening portion of the cavity, a tubular portion vertically provided on a rear surface of the cap body and configured to be fitted into a tubular inner surface of the cavity in a fitting direction, a contact portion facing an opening edge portion of the cavity, provided on the cap body, and located outward than a root of the tubular portion in a radial direction of the cap body, and a recessed portion provided on the rear surface of the cap body between the root of the tubular portion and the contact portion.