EV Connector Terminal Fastening Structure for Waterproof TPA
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Solution Overview
Problem
Angled type connectors face challenges in implementing a reliable terminal position assurance (TPA) structure due to weak fastening forces and compatibility issues with waterproof designs, particularly in high voltage connectors for electric vehicles.
Innovation Solution
A terminal fastening structure where a terminal holder is pre-fastened inside the connector housing, and a locking protrusion is used to secure the terminal, enhancing the terminal position guarantee and reinforcing the holding force through a combination of hooks and chamfered edges, along with a rotatable lever and shield shells for secure coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rear holder type retainer is used to hold the terminal position, then the connector can be assembled, but the terminal holding force is weak
Solution Approach 1:
The terminal holding function is divided into two independent components: the terminal holder (pre-fastened to housing) and the locking protrusion (on terminal). This segmentation allows each component to be optimized for its specific function, with the holder providing pre-positioning and the protrusion providing locking force, thereby resolving the contradiction between assembly ease and holding strength.
Solution Approach 2:
The terminal holder is pre-fastened to the housing during housing assembly, before the terminal is installed. This preliminary action ensures the holder is already in position to guide and support the terminal, providing initial positioning and preparing the structure for the subsequent locking action of the protrusion, thus enhancing overall terminal security.
2Reliability
If a TPA structure is inserted to ensure terminal position, then terminal positioning is improved, but it cannot be applied to waterproof connectors due to holes in housing
Solution Approach 1:
The TPA structure is extracted from the housing and relocated to the terminal itself (locking protrusion). This extraction eliminates the need for holes in the housing, thereby maintaining waterproof integrity while preserving the terminal position guarantee function. The protrusion on the terminal engages with the holder, achieving positioning without compromising housing密封性.
Solution Approach 2:
The terminal holder acts as an intermediary component that receives the locking protrusion from the terminal and transfers the positioning function to the terminal without requiring modifications to the housing. This intermediary structure enables TPA functionality in waterproof connectors by mediating between the terminal and the housing interface.
3Ease of manufacture
If conventional angled type connector fastening structure is used, then assembly is simple, but terminal holding force is weak
Solution Approach 1:
The fastening structure transitions from a static rear holder to a dynamic two-stage system: the static holder provides initial positioning, and the locking protrusion provides active locking engagement. This dynamic approach maintains assembly simplicity while significantly enhancing terminal holding force through the progressive engagement of holder then protrusion.
Data Source
AI summary
A terminal fastening structure of a connector for an electric vehicle includes a pair of tab terminals electrically connected to an electrical wire connector, a plug inner housing having an opening at a first end into which the tab terminals are inserted, and a pair of terminal holders fastened to the plug inner housing and fixing the tab terminals to the plug inner housing.