Detachable Cover for Electrical Connector Case
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Solution Overview
Problem
The existing power-supply connectors for electric vehicles and plug-in hybrid vehicles face issues with case damage, exposure to public wear, and increased maintenance costs due to the difficulty in replacing the case without disassembling the entire connector, which compromises security and design flexibility.
Innovation Solution
A connector design featuring a cover that attaches to the outside of the case, comprising a pair of cover bodies with a rocking member and receiving member for engagement, along with positioning members to secure the cover in place, allowing for easy attachment and detachment without exposing internal components, thus protecting the case and enabling design changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the case is made as an integral part of the assembled power-supplying connector, then the connector structure is secure and complete, but the case cannot be easily replaced when damaged, increasing maintenance cost
Solution Approach 1:
The connector is divided into separate functional modules: the case (housing), the cover (protective shell), and internal components (terminals, wire ends). This segmentation allows the cover to be independently replaced when damaged, without requiring disassembly of the entire connector or replacement of the case, thereby reducing maintenance costs and simplifying repair operations.
2Reliability
If bolts and nuts are used to fix the case bodies, then the case can be securely assembled, but the exposed fastening members allow easy disassembly, creating a security problem
Solution Approach 1:
The fastening function is extracted from the case assembly and transferred to the cover. The cover incorporates integrated locking features (such as snap-fit mechanisms or integrated clips) that engage with the case, eliminating the need for externally visible bolts and nuts. This maintains secure fixation while preventing easy unauthorized disassembly, as the cover itself becomes the protective barrier against tampering.
3Shape
If the design is painted on the outer surface of the case, then the aesthetic requirement is met, but the design is easy to be removed due to falling or long time use
Solution Approach 1:
Instead of painting directly on the case surface, the design is created as a separate decorative cover or overlay that can be attached to the case. This cover incorporates the aesthetic design elements and can be easily replaced if damaged, while the underlying case remains intact. This approach maintains the visual appearance while improving durability, as the design element becomes a replaceable component rather than a permanent surface treatment.
4Object-affected harmful factors
If a cover is added to protect the case, then the case is protected from damage and dirt, but the device complexity increases
Solution Approach 1:
The cover is designed to integrate multiple functions into a single component: it provides protective coverage for the case, incorporates fastening mechanisms for secure attachment, includes design elements for aesthetic appearance, and features locking mechanisms for security. By combining these functions into one unified cover structure, the overall device complexity is minimized compared to having separate components for each function.
Data Source
AI summary
A connector 1 includes: a connector housing 2; a case 3; and a cover 4. The connector housing 2 receives terminals. The case 3 is coupled to the connector housing 2, and receives ends of electric wires 7 connected to the terminals in the connector housing 2. The cover 4 includes a pair of cover bodies 41, 42, a locking arm, and a receiving member 6. The pair of cover bodies 41, 42 are attached to an outside of the case 3, and attached to each other to cover an outer wall 3b of the case 3. The locking arm is mounted on a one cover body 41. The receiving member is mounted on the other cover body 42 and engaged with the locking arm 41.