High-Voltage Connector Retaining Structure for Wire Vibration Resistance
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Solution Overview
Problem
Existing connector structures fail to effectively suppress the influence of vibration on electric wires, particularly those with larger diameters, which can lead to instability and potential disconnection when used in applications like automobile electric devices.
Innovation Solution
A connector design featuring an electric wire retaining portion with a securing-side retaining portion and an attachment retaining portion, which securely retains the electric wire through a housing with an elliptical or circular cross-section, and includes a pressing portion to enhance retention and prevent moisture ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a rigid electric wire with large diameter is used to handle increased voltage, then the voltage handling capability is improved, but the wire becomes more susceptible to vibration that may affect the connector
Solution Approach 1:
The connector housing is divided into multiple functional portions: an electric wire insertion portion for receiving the wire, a retaining portion for securing the wire, and a sealing portion for preventing moisture ingress. This segmentation allows each portion to be optimized independently for its specific function while working together to solve the overall problem of vibration resistance and protection.
Solution Approach 2:
The electric wire is retained by the retaining portion before the connector is fully assembled and before vibration occurs. The pressing portion applies preliminary pressing force to the electric wire to secure it in position, preventing vibration-induced movement before it can cause damage or disconnection.
2Reliability
If the electric wire is securely retained to suppress vibration influence, then the connection stability is improved, but the structure becomes more complex with multiple retaining portions
Solution Approach 1:
Multiple functions are merged into a single integrated housing structure. The housing combines the electric wire insertion portion, retaining portion with pressing portions, and sealing portion into one unified component, reducing the number of separate parts while maintaining vibration resistance and connection stability.
Solution Approach 2:
The housing serves multiple functions simultaneously: it provides structural support, retains the electric wire through the retaining portion, applies pressing force to secure the wire, and prevents moisture ingress through the sealing portion. This multi-functionality reduces overall system complexity while improving reliability.
3Reliability
If the electric wire insertion portion has a specific cross-sectional shape, then the wire retention is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The housing has different cross-sectional shapes at different locations to optimize local functions. The electric wire insertion portion has a specific cross-sectional shape for optimal wire retention, while other portions have shapes optimized for their specific functions. This local quality approach allows each region to be manufactured with precision tailored to its specific requirements rather than requiring uniform high precision throughout.
Data Source
AI summary
The object is to provide a connector and a connector connection structure that, even if an electric wire is vibrated, may suppress influence of the vibration.A housing 22, 23 includes an insertion cylinder 221,231 in communication with a main body 222, 232 and having a high-voltage electric wire 201 inserted thereinto. An electric wire retaining portion 28 provided on the harness insertion outer cylinder 231 and retaining the high-voltage electric wire 201 has an electric wire insertion hole 281 retaining the high-voltage electric wire 201 inserted thereinto, and further includes a securing-side retaining portion 282 provided on the harness insertion outer cylinder 231 and having securing-side arcked grooves 281a, and an attachment retaining portion 283 having attachment-side arcked grooves 281b and attached to the securing-side retaining portion 282.