Connector Guide Portion Decouples Current Capacity from Safety
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Solution Overview
Problem
Existing connector devices for high current applications, such as electric vehicle charging, face a challenge in increasing the diameter of male terminals to handle large currents while maintaining finger touch prevention for female terminals.
Innovation Solution
The connector device incorporates a guide portion made of insulating resin with a guide hole diameter larger than the male terminal, featuring protruding portions on the inner surface that fit into groove portions on the male terminal, ensuring electrical connection while preventing finger contact with the female terminal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the diameter of the male terminal is increased to realize large current, then the current carrying capacity is improved, but the diameter of the guide hole must also be increased which compromises finger touch prevention for the female terminal
Solution Approach 1:
The guide portion acts as an intermediary component between the guide hole and the male terminal. It features a guide hole with a larger diameter than the male terminal, allowing the male terminal to pass through easily, while protruding portions extend into the guide hole to create physical barriers that prevent finger access to the female terminal. This intermediary structure decouples the guide hole diameter from the finger touch prevention function.
Solution Approach 2:
The guide portion is segmented into distinct functional regions: the guide hole region with larger diameter for terminal passage, and the protruding portions that extend inward to block finger access. This segmentation allows each region to optimize its specific function - the guide hole accommodates the increased male terminal diameter while the protruding portions maintain safety by preventing finger contact with the female terminal.
2Power
If the diameter of the guide hole is increased to accommodate a larger male terminal, then the current capacity is improved, but the finger touch prevention for the female terminal deteriorates
Solution Approach 1:
The guide portion serves as a mediator that allows the guide hole to be enlarged for higher current capacity while preventing the harmful effect of finger access. The protruding portions within the guide hole create an intermediate barrier that blocks fingers from reaching the female terminal, thus resolving the contradiction between larger guide hole diameter and finger touch prevention.
Solution Approach 2:
The solution moves from a two-dimensional consideration (guide hole diameter) to a three-dimensional structure by adding protruding portions that extend radially inward from the guide hole wall. This dimensional addition creates blocking barriers without reducing the guide hole diameter, allowing both large current capacity and finger touch prevention to coexist.
Data Source
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AI summary
A connector device has a first connector including a male terminal which is rod-shaped, and a second connector including a female terminal to which the male terminal is electrically connected, in which the second connector includes an guide portion which is made of an insulating resin, the guide portion includes a hole portion for guiding the male terminal to the female terminal such that the hole portion is formed to have a diameter larger than an outer diameter of the male terminal, at least one groove portion is formed on an outer peripheral surface of the male terminal in an axial direction of the male terminal, and a protruding portion is provided on an inner peripheral surface of the hole portion, the protruding portion being inserted through the groove portion of the male terminal to be inserted into the hole portion and connected to the female terminal.