Connector Packing Retention via Mushroom Locking Projection
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Solution Overview
Problem
The existing connector design for three-phase AC motors in electric vehicles and hybrid automobiles has weak retentive strength for packing retention and lacks visual confirmation of the packing's presence, leading to potential detachment under external forces and hidden installation issues.
Innovation Solution
A connector design featuring a cap with a locking hole and a mushroom-like locking projection with an enlarged end portion, along with a pin member for increased stiffness, ensures reliable retention and visual confirmation of the packing's presence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the mushroom-like locking projection is caught by the recessed portion to be in locking engagement therewith, then the packing is retained by the cover member, but the retentive strength is weak and the packing may be inadvertently detached
Solution Approach 1:
The locking projection is designed with non-uniform cross-sectional area along its length, creating a localized enlarged end portion that provides enhanced engagement surface area and mechanical interlocking strength with the locking hole, while other portions maintain smaller dimensions for flexibility and assembly
Solution Approach 2:
The locking projection is constructed from composite material comprising a base material and a coating layer with different physical properties, where the coating layer provides enhanced friction and adhesion to the locking hole walls, significantly improving retentive strength beyond what the base material alone could achieve
2Ease of manufacture
If the packing does not have rigidity and the locking projection does not have rigidity, then the components are flexible and easy to install, but the retentive strength for retention of the locking projection and the recessed portion is further decreased
Solution Approach 1:
The locking projection features a localized enlarged end portion with increased cross-sectional area and structural reinforcement, providing high rigidity and strength at the critical engagement point while other portions remain flexible for ease of installation
Solution Approach 2:
The composite construction with a rigid coating layer on a flexible base material enables the locking projection to exhibit both flexibility during installation and high rigidity during operation, resolving the contradiction between ease of manufacture and retentive strength
3Volume of moving object
If the packing is arranged between the cover member and the terminal fitting accommodating portion, then the connector components are compact, but the packing cannot be visually recognized and installation verification is not possible
Solution Approach 1:
The packing is provided with a distinctive color or visual marking that contrasts with surrounding components, enabling easy visual recognition and verification of proper installation while maintaining the compact arrangement between the cover member and terminal fitting accommodating portion
Data Source
AI summary
A connector comprises a connector housing receiving therein a terminal fitting connected to an electrode of a connector-mounting portion and an electrical wire at an end of which the terminal fitting is provided; a cap for the connector housing; and a packing for the cap. The packing includes a mushroom-like locking projection with an enlarged end portion. The cap includes a locking hole into which the end portion of the locking projection is inserted so that the end portion is placed in locking engagement with the locking hole.