Electrical Connector Touch Protection for Insertion Force
Solution Overview
Problem
Existing connectors for high-power applications in hybrid and electric vehicles face issues with insertion performance and insulator wear due to contact between the male terminal's insulator and the female terminal's protrusions or spring mechanisms, leading to increased insertion force and potential damage.
Innovation Solution
A connector design featuring a male terminal with a U-shaped cross-section and a touch protecting mechanism using insulating rubber caps and projecting portions within the terminal housing to prevent direct contact with foreign objects, maintaining insertion performance while protecting the male terminal from touch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an insulator is disposed at the top end of the male terminal to protect it from being touched, then the male terminal is protected from direct contact with foreign bodies, but the insulator contacts the protrusion or spring portion in the female terminal during insertion, increasing insertion force and reducing insertion performance
Solution Approach 1:
The protection structure is divided into two separate components: the insulating portion covering the top end of the male terminal, and the projecting portions formed on the terminal housing. This segmentation allows the insulator to protect the terminal without contacting the female terminal's internal components during insertion, as the projecting portions provide structural support and positioning separately.
Solution Approach 2:
The projecting portions act as intermediary elements between the male terminal and the female terminal's holding means. They provide the necessary contact points for insertion and positioning without allowing the insulating portion to interfere with the electrical contact components, thus mediating between protection requirements and insertion functionality.
2Object-affected harmful factors
If the insulator covers the entire male terminal including the contact portion, then protection from foreign bodies is maximized, but the contact portion cannot make proper contact with the holding means in the female terminal
Solution Approach 1:
The insulating portion is designed to cover only specific areas of the male terminal (the top end and sidewalls) while deliberately leaving the bottom portion and contact areas exposed. This local differentiation ensures that protection is applied where needed (preventing foreign body contact) while maintaining functionality where contact is required (electrical connection with holding means).
Data Source
AI summary
A connector includes a male connector part composed of a male terminal, a first main body to which the male terminal is attached, and a first terminal housing portion composed of a first housing opening portion in which an end of the male terminal is exhibited and a predetermined housing space in which the male terminal is housed, a female connector part composed of a female terminal into which the male terminal is inserted, the male terminal being electrically connected to the female terminal by fitting the male connector part with the female connector part, a holding means inside the female terminal for holding the male terminal in a vertical direction, and a touch protecting means inside the first terminal housing portion for protecting the male terminal housed in the predetermined housing space from being touched by a foreign body. The touch protecting means includes an insulating portion for covering a part of the male terminal including the end of the male terminal except a part contacting the holding means when the male terminal is inserted into the female terminal, and a pair of projecting portions projecting in the predetermined housing space of the first terminal housing portion and at a position opposite the part contacting the holding means when the male terminal is inserted into the female terminal such that the male terminal is sandwiched therebetween in the vertical direction.