Connector-Mounting Structure for Vibration Load Distribution
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Solution Overview
Problem
Existing connector-mounting structures in hybrid and electric vehicles, which absorb positional deviations using rubber packings, face reliability concerns due to uneven load distribution during vibrations, as the load primarily acts on the packing rather than being distributed across the structure.
Innovation Solution
A connector-mounting structure featuring a case with a through-hole, a connector with a flange portion and a waterproof elastic member, and a connector holding plate with a recess and housing insertion hole, allowing the connector to slide and distribute the load, ensuring waterproofness and enhanced reliability during positional deviation absorption and vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a rubber packing is sandwiched between the inverter case and the connector to absorb positional deviation, then the connector can accommodate positional misalignment, but the load acts only on the packing which reduces reliability under vibration
Solution Approach 1:
The connector mounting structure is divided into multiple load-bearing components: the connector holding plate, the flange portion, and the waterproof elastic member. Each component serves a specific function - the holding plate provides structural support, the flange distributes load, and the elastic member handles sealing and minor positioning, collectively improving reliability while maintaining adaptability
Solution Approach 2:
The mounting structure combines rigid components (connector holding plate, flange portion) with elastic components (waterproof elastic member) to create a composite system. This allows the structure to simultaneously provide mechanical strength for load distribution and elastic deformation for positional deviation absorption, resolving the contradiction between reliability and adaptability
2Stability of the object's composition
If the connector housing outer size is larger than the through-hole size, then the connector can be securely mounted in the case, but the connector cannot slide to absorb positional deviation
Solution Approach 1:
The connector structure is segmented into the connector housing (for stable mounting with larger size) and the insertion portion (for sliding through the through-hole). This segmentation allows the housing to provide mounting stability while the insertion portion enables positional adjustment through sliding motion
Solution Approach 2:
The connector holding plate acts as an intermediary between the connector housing and the case. It provides a mounting surface that secures the connector while allowing the insertion portion to slide, thus mediating between the conflicting requirements of stable mounting and positional adaptability
3Device complexity
If the waterproof elastic member is the only component absorbing positional deviation, then the structure is simple, but the load concentration on the elastic member reduces reliability
Solution Approach 1:
The connector holding plate serves multiple functions: it provides structural support, distributes load from the connector, and enables sliding motion for positional adjustment. The flange portion similarly serves as both a mounting feature and a load-distributing element. This multi-functionality increases complexity slightly but dramatically improves reliability by distributing loads across multiple components
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
This configuration secures higher reliability by distributing the load across the structure rather than solely on the waterproof elastic member, maintaining stability and connectivity between connectors, even under vibration, thereby enhancing the absorption of positional deviations.
Implementation Method 1
a waterproof elastic member disposed outside the connector housing... the waterproof elastic member has a sealing portion that faces the first surface of the flange portion and is provided so as to be in sliding contact with the inner surface of the case
Data Source
AI summary
A connector-mounting structure includes a case and a connector mounted on the case. The connector has a connector housing, a terminal, a waterproof elastic member, and a connector holding plate fixed to an inner surface of the case. An outer size of the connector housing is larger than a hole size of a through-hole of the case. The waterproof elastic member has a sealing portion. A size of a recess of the connector holding plate is larger than an outer size of a flange portion of the connector housing. A hole size of a housing insertion hole of the connector holding plate is larger than an outer circumferential size of a main body of the connector housing. An outer circumferential size of the insertion portion is smaller than the hole size of the through-hole.