E-bike Plug Connector Sealing and Locking Mechanism
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Solution Overview
Problem
Existing electrical connectors for electric bicycles, particularly those located in the bottom bracket area, face challenges with water exposure and lack of a secure, fixed connection, as they are often designed as flying plug connections with limited space and no direct separation option within the motor housing.
Innovation Solution
A plug connector with a circumferential sealing element and an outwardly projecting locking element that secures the connector in place, ensuring sealing and locking when plugged in, combined with a hotmelt material for additional sealing and stabilization of the cable harness, and alignment elements for correct polarity insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a flying plug connection is used in the middle of a cable, then the electrical connection can be made at some distance from the motor housing, but the connection is exposed to spray water and has limited space for secure mounting
Solution Approach 1:
The patent introduces an intermediary sealing structure (O-ring seal) between the electrical connector and the environment. The seal acts as a mediator that blocks water spray from reaching the electrical contacts while allowing the connector to remain accessible for connection operations.
2Volume of moving object
If the electrical plug connection is arranged away from the motor housing, then there is more space for cable routing, but the connection lacks secure fixed mounting and can detach unintentionally
Solution Approach 1:
The connector incorporates a dynamic locking mechanism with spring-loaded locking elements that automatically engage with corresponding recesses in the mating connector. This dynamic system provides secure fixation during normal operation while allowing intentional disconnection when needed.
3Reliability
If a locking mechanism is added to prevent unintentional detachment, then the connection stability improves, but the device complexity increases
Solution Approach 1:
The patent merges multiple functions into a single integrated connector body: the sealing function (O-ring), the locking function (spring-loaded elements with recesses), and the electrical contact function are all combined in one compact assembly. This reduces overall system complexity compared to separate components.
4Object-affected harmful factors
If a circumferential sealing element is added around the plug contacts, then the water protection improves, but the manufacturing complexity increases
Solution Approach 1:
The patent employs a flexible O-ring seal that can be easily molded and installed around the connector body. This thin-film sealing solution provides effective water protection without requiring complex manufacturing processes or assembly steps.
Data Source
Figure 1~2
Figure 3~4a
Figure 4b
AI summary
The invention relates to a connector (1) for an electrical connection of an electric bicycle (3), comprising a plurality of electrical plug contacts (10, 10') and a connector wall (11) that circumferentially surrounds the plug contacts (10, 10'), characterized in that an outer surface (12) of the connector wall (11) is provided with a circumferential sealing element (14) and that an outwardly projecting locking element (15) is arranged on the outer surface (12) of the connector wall (11). The sealing element (14) seals the plug contacts (10, 10') in a suitable socket. Furthermore, the locking element (15) secures the connector (11) against accidental disconnection. The connector is space-saving, allowing multiple connections to be accommodated in a confined space.