EV Charging Connector Support Member Prevents Sealing Sliding
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Solution Overview
Problem
The existing charging connectors for electric vehicles have high manufacturing costs and a sealing structure that lacks support performance, causing the sealing member to slide inward along terminal pins during strong coupling, leading to reduced sealing effectiveness.
Innovation Solution
A charging connector design featuring a connector housing with terminal pin mounting openings, a sealing member at the rear, a support member with a larger outer diameter than the sealing member to prevent sliding, and a rear holder for stable cable insertion, along with optional protrusion members for enhanced coupling, ensuring the sealing member remains in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a sealing member is fitted into the cable joint part to support terminal pins, then moisture and impurities are prevented from intruding, but the sealing member slides forward when coupled with excessive force
Solution Approach 1:
The support member is pre-installed in the connector housing before the sealing member is fitted. This preliminary structural preparation provides a physical barrier that prevents the sealing member from sliding forward during coupling, while still allowing the sealing member to perform its moisture and impurity prevention function effectively.
Solution Approach 2:
The support member acts as an intermediary element between the connector housing and the sealing member. It provides mechanical support and positioning for the sealing member, preventing direct contact between the sealing member and the terminal pins that would cause sliding during excessive force coupling.
2Stability of the object's composition
If terminal pin receiving members and lance are used to support terminal pins, then terminal pins are secured, but manufacturing costs are high and the structure is difficult to mold
Solution Approach 1:
The invention extracts and eliminates the complex lance structure and separate terminal pin receiving members from the design. Instead, a simplified support member is used that provides the necessary terminal pin support function while being much easier to manufacture and mold as a single component.
Solution Approach 2:
The support member serves multiple functions: it supports the terminal pins, provides structural reinforcement, and prevents the sealing member from sliding. This multi-functional design replaces the previous multi-component system (lance + receiving members), reducing manufacturing complexity and cost.
3Ease of operation
If the sealing member is fitted loosely to allow easy assembly, then assembly is simplified, but the sealing member may slide forward along the terminal pins
Solution Approach 1:
The support member is pre-installed to create a physical constraint that guides and limits the movement of the sealing member during assembly. This preliminary structural preparation allows the sealing member to be fitted easily without excessive force while preventing it from sliding forward once installed.
Solution Approach 2:
The support member changes the mechanical parameters of the assembly system by providing a physical barrier that limits the displacement of the sealing member. This allows the sealing member to be fitted with appropriate clearance for easy assembly while maintaining reliable sealing performance under operational conditions.
Data Source
AI summary
Provided is a charging connector for an electric vehicle including a connector housing having at least two terminal pin mounting openings, at least two terminal pins inserted into the terminal pin mounting openings such that front ends of the terminal pins are exposed through a front end of the connector housing, a sealing member arranged at the rear of the terminal pins in the connector housing, a support member arranged in front of the sealing member to prevent the sealing member from moving toward the front ends of the terminal pins, the support member having an outer diameter greater than an inner diameter of the sealing member, and a rear holder connected to a rear end of the connector housing in a close contact with a rear end of the sealing member, and having cable insertion openings corresponding to the terminal pins, through which a power cable is inserted.