Electric Connector Mounting Structure Using Integrated Sealing
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Solution Overview
Problem
Existing electric connectors for electric vehicles have complex manufacturing processes and high costs due to the need for additional components like bolt connection parts and connector installing bolts, which complicate assembly and increase costs.
Innovation Solution
An electric connector with a simplified mounting structure that omits bolt connection parts and uses a press-fitting mechanism with a two-stage insertion part and a deformable sealing ring to ensure secure electrical connection and sealing without the need for additional bolts, reducing manufacturing complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bolt connection parts and connector installing bolts are used to secure the electric connector, then the sealing function and electrical connection stability are improved, but the manufacturing complexity and assembly costs increase
Solution Approach 1:
The patent combines the sealing function and mounting function into a single integrated sealing member. The sealing member includes a sealing body that directly contacts the housing to provide sealing, while also incorporating mounting protrusions that engage with mounting grooves to secure the connector. This eliminates the need for separate bolts and mounting parts, reducing structural complexity while maintaining reliable sealing.
Solution Approach 2:
The sealing member is designed to perform multiple functions simultaneously: it provides the sealing function to prevent dust and water ingress, acts as a mounting structure through its protrusions and grooves, and ensures electrical connection stability. This multi-functional design replaces the traditional separate components (sealing ring + bolts + mounting parts) with a single integrated element.
2Reliability
If bolt connection parts and connector installing bolts are used to secure the electric connector, then the electrical connection stability is improved, but the assembly costs and manufacturing complexity increase
Solution Approach 1:
The patent merges the sealing member and mounting structure into a single integrated component. The sealing member includes mounting protrusions that engage with mounting grooves formed directly on the housing, eliminating the need for separate bolts and mounting parts. This reduces the number of manufacturing steps and assembly operations while ensuring stable electrical connection through secure mounting.
Solution Approach 2:
The patent extracts and eliminates the unnecessary bolt connection parts and connector installing bolts from the traditional design. By removing these extra components and replacing them with an integrated sealing member that includes built-in mounting features, the manufacturing process is simplified and assembly costs are reduced while maintaining connection stability.
3Reliability
If a traditional mounting structure with bolts is used, then the sealing function is provided, but the assembly process becomes complex and costly
Solution Approach 1:
The patent combines the sealing function and mounting function into a single integrated sealing member with built-in mounting protrusions. This allows the connector to be assembled by simply inserting and engaging the sealing member with the housing, eliminating the need for separate bolt tightening operations and significantly improving assembly efficiency while maintaining reliable sealing.
Solution Approach 2:
The sealing member is pre-designed with integrated mounting protrusions that automatically engage with the mounting grooves on the housing during insertion. This preliminary integration of mounting features eliminates the need for separate mounting steps, streamlining the assembly process and improving productivity while ensuring proper sealing from the outset.
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 provides a cost-effective and efficient assembly process while maintaining a stable sealing function and secure electrical connection, reducing the risk of horizontal vibration and ensuring durability against dust and water ingress.
Implementation Method 1
a deformable sealing ring to ensure secure electrical connection and sealing
Implementation Method 2
uses a press-fitting mechanism with a two-stage insertion part
Data Source
AI summary
Provided is an electric connector for connecting electric equipment to a power device. The electric connector includes a connector body defining an outer appearance thereof, a connection bar disposed on the connector body to electrically the connect electric equipment to the power device, an insertion part disposed on the connector body, the insertion part being inserted into the electric equipment, and a sealing disposed on a shaft of the insertion part in a circumferential direction.