EV Connector Partition Wall Prevents Interlock Collision
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Solution Overview
Problem
In connectors for electric vehicles, the first interlock terminal may collide with or make contact with bolts or terminal fittings when the cover is closed, and the cover cannot be properly positioned due to the placement of the second interlock terminal, leading to potential damage and improper assembly.
Innovation Solution
A connector design featuring a terminal receiving portion with a bolting chamber, an insertion hole, and a partition wall that separates the bolting chamber from the insertion hole, where the second interlock connector is positioned to prevent collisions and ensure proper cover alignment, allowing the first interlock connector to be inserted into the insertion hole and fitted with the second interlock connector for secure conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the second interlock terminal is provided in the bolting chamber lower than the terminal fitting, then the cover can cover the bolting chamber, but the first interlock terminal may collide with or make contact with the bolt and terminal fitting
Solution Approach 1:
The bolting chamber is divided into two separate spaces by a partition wall: a first space for receiving the terminal fitting and a second space for receiving the bolt. The first interlock terminal is positioned in the second space, while the second interlock terminal is positioned in the first space, physically separating the interlock terminals from potential collision hazards.
Solution Approach 2:
A partition wall is introduced as an intermediary structure between the first interlock terminal and the bolt/terminal fitting. This partition wall prevents direct contact and collision while allowing both components to function within their respective spaces.
2Reliability
If the second interlock terminal is provided lower than the terminal fitting, then the interlock terminals can be fitted, but the cover cannot be positioned until the first and second interlock terminals are fitted
Solution Approach 1:
The partition wall is pre-installed in the bolting chamber, establishing the spatial boundaries before the interlock terminals are fitted. This preliminary structure guides the fitting process and enables cover positioning to occur independently of the interlock terminal assembly sequence.
3Ease of manufacture
If the cover is pushed to the bolting chamber while displaced, then the cover can be assembled, but the packing member may be gouged by an opening edge
Solution Approach 1:
The partition wall is installed beforehand to create proper spatial boundaries and alignment references. This preliminary structure ensures that when the cover is pushed onto the bolting chamber, the packing member is properly positioned and protected from damage by opening edges.
Data Source
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AI summary
An object of the present invention is to provide a connector able to prevent a first interlock connector from making contact with a bolt, a terminal fitting, or the like, and able to position a cover for covering a bolting chamber. The connector (1) includes: the terminal receiving portion (17) provided with the terminal fittings (12a to 12f) to be connected to the electrodes (44a to 44f) of the connector attachment portion (2); the cover member (6) for covering the terminal receiving portion (17); the first interlock connector (28) projecting from the cover member (6); and the second interlock connector (39) provided on the terminal receiving portion (17) and configured to be fitted to the first interlock connector (28). When the cover member (6) covers the terminal receiving portion (17), the first interlock connector (28) and the second interlock connector (39) are fitted to each other, thereby the connector (1) detects that the cover member (6) covers the terminal receiving portion (17) and allows the terminal fittings (12a to 12f) to be energized with the electrodes (44a to 44f) of the connector attachment portion (2). The terminal receiving portion (17) is provided with: the bolting chambers (11a, 11b) in which the terminal fittings (12a to 12f) and the electrodes (44a to 44f) are fastened with bolts; the insertion hole (16) into which the first interlock connector (28) is inserted; and the partition wall (15) separating the bolting chambers (11a, 11b) from the insertion hole (16). Further, the second interlock connector (39) is provided at a position corresponding to the insertion hole (16).