High-Voltage Connector Tapered Rib Terminal Insertion
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Solution Overview
Problem
Conventional high voltage connectors with rigid connector housings made of high thermal resistance materials, such as glass-reinforced resin, face issues with terminal engagement due to the application of large external forces, which can lead to damage of engaging protrusions and reduced engagement force.
Innovation Solution
The design incorporates a connector housing with tapered and straight ribs on partition walls, and notched portions on the terminals, allowing for inclined insertion and reduced external force application during terminal mounting, ensuring secure engagement without damaging the engaging protrusions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the connector housing is formed of a high rigid material (glass-reinforced resin) to achieve high thermal resistance, then the connector housing becomes a high rigid structure with good thermal properties, but large external force is applied to the engaging protrusions during terminal insertion, causing corner portions of the engaging protrusions to be cut off and reducing engagement force
Solution Approach 1:
A tapered rib is introduced as an intermediary structure between the rigid connector housing and the terminal. This tapered rib gradually guides the terminal into the terminal housing portion, mediating the interaction between the rigid housing and the terminal to prevent direct impact on the engaging protrusions. The tapered rib absorbs and distributes the insertion force, preventing corner portions of the engaging protrusions from being cut off while maintaining the high thermal resistance properties of the rigid connector housing.
2Strength
If the connector housing is formed of a high rigid material, then the structural strength and thermal resistance are improved, but the engaging protrusions are damaged during terminal mounting due to large external force application
Solution Approach 1:
The tapered rib serves as a mediator that guides the terminal into proper alignment with the engaging protrusions. By gradually directing the terminal along its insertion path, the tapered rib ensures precise engagement without the large external forces that would otherwise damage the protrusions or compromise engagement precision.
3Ease of operation
If the terminal is inserted directly into the terminal housing portion, then the insertion process is simple, but large external force is applied to the engaging protrusions causing them to be cut off
Solution Approach 1:
The tapered rib performs a preliminary guiding action before the terminal reaches the engaging protrusions. By pre-aligning and gradually directing the terminal into the terminal housing portion, the tapered rib prepares the insertion path in advance, allowing the terminal to be inserted without applying large external forces to the engaging protrusions. This preliminary guidance maintains insertion simplicity while preventing damage.
Data Source
Figure 1
Figure 2~4
Figure 5~6
AI summary
A high voltage connector (1) includes: a connector housing (2) formed of a high rigid material, and having a terminal housing portion (3) in which both sides are partitioned by a first partition wall (5) and a second partition wall (6), an engaging protrusion (7) provided on the first partition wall (5) side, and a tapered rib (8) that is provided on the second partition wall (6) side and is inclined in a direction of gradually protruding into the terminal housing portion (3) as going from an inlet side of the terminal housing portion (3) toward a depth of the terminal housing portion (3); and a terminal (10) to be housed in the terminal housing portion (3).