Integrated Connector Shells for Misalignment-Tolerant Plugging
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Solution Overview
Problem
The heavy weight of battery packs during assembly leads to impact forces when guiding posts are inserted, causing guiding failure due to misalignment, resulting in broken guiding structures.
Innovation Solution
A connector design featuring a first plug core with a guiding shell and a second plug core with an assembly shell, where the assembly shell has a larger cross-sectional area than the guiding shell, allowing for a sliding fit and guiding slopes and ribs to facilitate alignment and plugging without separate guiding structures, enhancing stability and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate guiding structures (guiding posts and guiding holes) are provided on both sides of the plug core, then the likelihood of misalignment during plugging is reduced, but the guiding posts may break due to impact force from heavy battery pack weight during assembly
Solution Approach 1:
The patent combines the guiding function and the sealing function into a single integrated structure. The guiding shell serves both as the guiding structure for alignment and as the sealing structure for protecting internal components, eliminating the need for separate guiding posts and guiding holes that are prone to breaking under impact forces during assembly
Solution Approach 2:
The plug core is divided into functional modules: the guiding shell (with guiding and sealing functions), the housing (with protective and structural functions), and the terminal components. This segmentation allows each module to be optimized independently while maintaining overall system performance
2Manufacturing precision
If separate guiding structures are provided on both sides of the plug core, then alignment during plugging is improved, but the device complexity increases due to additional components
Solution Approach 1:
The guiding shell integrates multiple functions (guiding, sealing, and structural support) into a single component, reducing the total number of parts and simplifying the overall structure while maintaining precise alignment capabilities during plugging operations
3Reliability
If the assembly is performed with heavy battery packs that cannot be installed in a perfectly vertical orientation, then the impact force causes guiding posts to break, but providing more robust guiding structures increases device complexity
Solution Approach 1:
The guiding shell combines guiding and sealing functions in one integrated structure that is more reliable under impact conditions, eliminating the need for complex reinforcement of separate guiding posts while maintaining guiding function reliability during assembly operations with heavy battery packs
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
Ensures stable and efficient plugging by eliminating the need for separate guiding structures, reducing material usage, lowering production costs, and prolonging the connector's service life while improving installation efficiency and adaptability.
Implementation Method 1
a cross-sectional area of the assembly shell is larger than a cross-sectional area of the guiding shell, and a guiding gap for the insertion of the guiding shell is formed between an inner side of the assembly shell and the male barrel. An inner side wall of the assembly shell is in sliding fit with an outer side wall of the guiding shell
Implementation Method 2
a guiding slope in sliding match with the assembly shell is provided on the outer side wall of the guiding shell
Data Source
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AI summary
This application relates to the technical field of electrical device, and discloses a connector including a first plug core and a second plug core. The first plug core includes a first body and a guiding shell. The guiding shell is arranged in the first body. A female barrel for the insertion of a male pin is arranged in the guiding shell. The second plug core includes a second body and an assembly shell. The assembly shell is arranged in the second body and is configured to plug and match with the guiding shell. A male barrel for the plugging and matching with the female barrel is arranged in the assembly shell. Therefore, when the first plug core is plugged with the second plug core, the plugging is quickly completed by using the guiding relationship between the guiding shell and the assembly shell. Moreover, the guiding shell and the assembly shell can be respectively formed by protruding extensions of the first body and the second body themselves, so that the first plug core and the second plug core do not need to be provided with a separate guiding structure. Thereby, the guiding effect of the guiding structure can be effectively ensured, reducing the likelihood of guiding function failure, which is beneficial for ensuring the stable performance of the connector and prolonging its service life.