Modular EV Connector Structure with Sealed Unused Ports
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Solution Overview
Problem
The increasing number of components due to differences in car models and specifications, such as HEV, PHEV, and BEV, necessitates frequent redesigns of connector groups, leading to increased design and manufacturing man-hours and costs, as well as a larger connector fitting structure.
Innovation Solution
A connector structure for electric vehicles that includes multiple connectors with an inter-connector conductive member and a casing, allowing for easy attachment of a cover to unused connectors, reducing the need for shape changes and enabling a compact, waterproof/dust-proof design, with separable casings and electrical connections that eliminate the use of bolts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of components increases due to different car models and specifications, then the power supply capability is improved, but the connector group requires frequent redesign leading to increased design and manufacturing man-hours
Solution Approach 1:
The patent applies universality by designing a standardized connector group structure that can serve multiple car models and specifications. The connector group maintains a common basic structure while accommodating different numbers of components through selective installation, eliminating the need for frequent redesigns when adapting to different vehicle configurations.
Solution Approach 2:
The connector group is segmented into modular units that can be independently installed or removed. This segmentation allows the same basic connector group structure to adapt to different component quantities by simply installing or removing specific modules, rather than redesigning the entire connector group for each configuration.
2Adaptability or versatility
If the number of components increases due to different car models and specifications, then the power supply capability is improved, but the manufacturing cost increases
Solution Approach 1:
The standardized connector group design allows a single manufacturing process to produce connectors suitable for multiple car models and specifications. This universality reduces manufacturing costs by eliminating the need for separate production lines or tooling for different configurations, while still providing the capability to supply power to varying numbers of components.
3Object-affected harmful factors
If a cover is attached to an unused connector, then waterproof and dustproof performance is improved, but the connector structure complexity increases
Solution Approach 1:
The cover is merged with the connector structure as an integrated component rather than a separate attachment. This integration achieves waterproof and dustproof performance while minimizing structure complexity, as the cover becomes part of the standardized connector group design rather than an additional element.
4Adaptability or versatility
If the connector group is redesigned frequently to accommodate different component numbers, then the adaptability to different models is improved, but the design man-hours increase
Solution Approach 1:
The connector group is designed as a universal platform that can accommodate different car models and specifications without requiring redesign. The standardized structure with selective module installation capability allows the same design to serve multiple purposes, eliminating the need for frequent design iterations and reducing design man-hours significantly.
Solution Approach 2:
The connector group is designed in advance with predetermined installation positions and standardized interfaces that can accommodate different numbers of components. This preliminary action of creating a flexible baseline design eliminates the need for subsequent redesigns when adapting to different model requirements.
Data Source
AI summary
A connector structure installed in the electric vehicle includes a plurality of connectors, an inter-connector conductive member configured to electrically connect the plurality of connectors, and a connector casing configured to house the inter-connector conductive member. A cover is attached to the unused connector of the plurality of connectors.