Inter-Component Connector With Insulating Color Cues
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Solution Overview
Problem
Conventional power conversion devices in electric vehicles face challenges in downsizing while maintaining effective electrical connections, as visual confirmation issues during assembly can lead to misfitting of components, resulting in electrical connection failures, and existing solutions like resin components increase costs and working time.
Innovation Solution
An inter-component connection structure featuring a male and female fitting member with a flat plate-shaped insertion portion and Y/X-shaped nipping portions, respectively, that provide a larger contact area and adjustable insertion height, along with an insulating portion to prevent misfitting and detect connection failures through electrical inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If circuit boards are stacked to downsize power conversion devices, then mounting area is maintained and device size is reduced, but visual confirmation during assembly becomes difficult leading to fitting errors
Solution Approach 1:
The patent applies color changes by providing insulating portions with different colors (first color on male fitting member, second color on female fitting member) that are visible from the outside. This allows operators to visually confirm proper fitting of connectors even when circuit boards are stacked, resolving the contradiction between device downsizing and assembly ease.
2Reliability
If resin components are attached to fitting portions to prevent misfitting, then electrical connection reliability is improved, but cost and working time increase
Solution Approach 1:
The patent merges the insulating function and visual indication function into the connector structures themselves. The insulating portions are integrated parts of the male and female fitting members, eliminating the need for separate resin components while maintaining reliability and providing visual feedback.
Solution Approach 2:
The insulating portions serve multiple functions: they provide electrical insulation to prevent short circuits, offer visual indication of proper fitting through color differentiation, and structurally define the fitting interface. This multi-functionality replaces multiple separate components with a single integrated solution.
3Reliability
If insulating portions are provided on fitting members, then misfitting detection is enabled and electrical connection reliability is improved, but device complexity increases
Solution Approach 1:
The patent applies local quality by providing insulating portions only at specific locations on the fitting members where insulation and visual indication are needed, rather than making the entire connector complex. The insulating portions are strategically placed to provide functionality with minimal added complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively suppresses electrical connection failures by ensuring proper fitting, reducing contact resistance, and allowing for easier visual inspection, while also improving heat dissipation and preventing metal contamination, thus enhancing the reliability and efficiency of power conversion devices.
Implementation Method 1
The first nipping portion and the second nipping portion are respectively bent to form protruding portions toward surfaces thereof facing each other
Data Source
AI summary
An inter-component connection structure includes a male fitting member; and a female fitting member that has a first nipping portion and a second nipping portion disposed to face each other, and nips an insertion portion of the male fitting member inserted between the first nipping portion and the second nipping portion. A pair of the male fitting member and the female fitting member is disposed in different components. The first nipping portion and the second nipping portion are respectively bent to form protruding portions toward surfaces thereof facing each other. A gap is provided at a tip portion of each of the first nipping portion and the second nipping portion. In at least one of the pair of the male fitting member and the female fitting member, an insulating portion is provided in a region that is not in contact with the other when fitted.