Connector With Integrated Discharge Flow Path
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Solution Overview
Problem
The existing connector designs for electrical components, such as clutch actuators, face challenges with complex manufacturing processes, increased costs, and reduced design flexibility due to separate discharge ports for heat and gas, as well as poor bonding between plastic housings and metal terminals, leading to quality and reliability issues.
Innovation Solution
A connector design that integrates a terminal protruding into and out of a case, with an inner housing and pad for enhanced bonding, and a housing surrounding the inner housing and pad, featuring a discharge flow path and shielding film to eliminate the need for separate discharge structures, allowing for reduced component count and improved thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a separate discharge port is provided on the housing for discharging heat and gas, then heat and gas can be discharged from the housing, but the manufacturing process becomes complicated and manufacturing cost increases
Solution Approach 1:
The patent combines the discharge port function with the connector structure by forming the discharge port at the bottom surface of the connector housing, merging two separate components (discharge port and connector) into one integrated structure. This eliminates the need for separate discharge ports on the main housing, simplifying the manufacturing process and reducing assembly steps while maintaining effective heat and gas discharge capability.
2Temperature
If a separate discharge port is provided on the housing, then heat and gas can be discharged, but the housing requires more space for component arrangement
Solution Approach 1:
The discharge port is integrated into the connector housing structure at its bottom surface, combining the functions of the connector and discharge port into a single component. This eliminates the need for separate discharge port openings on the main housing surface, thereby preserving housing space for other component arrangements and contributing to product downsizing.
3Ease of manufacture
If the housing is manufactured by molding with terminals disposed inside, then the housing and terminal can be bonded, but a gap may form between the housing and terminal due to heat generation
Solution Approach 1:
The patent divides the housing into two separate components: the main housing and the connector housing. The terminal is disposed inside the connector housing, which is then coupled to the main housing. This segmentation allows the terminal to be precisely positioned and fixed within the connector housing before assembly, preventing gaps and position deviations that would occur if the terminal were directly molded into the main housing.
Solution Approach 2:
The terminal is pre-positioned and fixed within the connector housing before the connector housing is coupled to the main housing. This preliminary action ensures the terminal is securely held in its correct position, preventing gaps and position deviations during the subsequent assembly process and final product operation.
4Strength
If plastic housing and metal terminal are bonded directly, then the housing and terminal can be connected, but the bonding strength is low due to different coefficients of thermal expansion and low adhesive force
Solution Approach 1:
The patent introduces an intermediate connector housing component that mediates between the plastic main housing and the metal terminal. The terminal is fixed within the connector housing, which is then coupled to the main housing. This segmentation avoids direct bonding between dissimilar materials (plastic and metal), eliminating the bonding strength problem caused by different thermal expansion coefficients and low adhesive force.
Data Source
AI summary
The present invention relates to a connector which is disposed outside a case, the connector comprising: a terminal protruding at one end thereof into the case and protruding at the other end thereof out of the case; an inner housing coupled to the terminal so as to allow the terminal to protrude at the one end and the other end thereof; a pad disposed on one surface of the inner housing; and a housing completely surrounding the inner housing and the pad, wherein the housing comprises: a protrusion portion protruding from one surface of the case; and a mounting portion having a terminal groove in which the other protruding end of the terminal is placed.