Foldable Connector Cap Structure for Shorter Mating Stroke
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Solution Overview
Problem
Existing connectors for electric vehicles and hybrid vehicles require a larger space for the stroke of the connector due to the design of the cap, which interferes with the terminal accommodating wall, necessitating an increased size to prevent exposure and ensure dustproofing and terminal protection.
Innovation Solution
A connector design featuring a foldable cap with a rotating shaft and contact portion that moves along a rail, allowing the cap to fold and open without increasing the stroke size, utilizing a torsion coil spring for closure, thus reducing the required space for the connector's stroke.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the cap is designed to rotate around a pin to open and expose terminals, then terminal exposure and connection are enabled, but the connector stroke size increases due to the cap's distance from mounting position to end
Solution Approach 1:
The cap is divided into a first cap portion and a second cap portion that can rotate relative to each other around a pin. The first cap portion rotates to open the terminal exposing portion, while the second cap portion follows a different trajectory that does not interfere with the terminal accommodating wall. This segmentation allows the cap to fulfill its protective and exposing functions without requiring excessive stroke length.
Solution Approach 2:
The cap's opening motion is transformed from a simple linear rotation around a single pin to a more complex two-stage motion where the first cap portion rotates around a pin and the second cap portion rotates around a cap pin. This dimensional change in the motion path allows the cap end to clear the terminal accommodating wall while still achieving terminal exposure.
2Reliability
If the connector stroke is increased to accommodate the cap's rotation trajectory, then the cap can open without interfering with the terminal accommodating wall, but the overall connector size increases
Solution Approach 1:
The cap is segmented into two portions with different rotational characteristics. The first cap portion rotates around a pin to expose terminals, while the second cap portion rotates around a cap pin to follow a trajectory that avoids the terminal accommodating wall. This segmentation allows the connector to maintain compact dimensions while ensuring reliable terminal protection and dustproofing when closed.
3Stability of the object's composition
If the cap is designed with a fixed mounting position to ensure stable terminal protection, then protection reliability is improved, but the stroke size must be increased to avoid interference with the terminal accommodating wall
Solution Approach 1:
The cap is divided into a first cap portion mounted on a pin and a second cap portion mounted on a cap pin. The first cap portion provides stable terminal protection when closed, while the second cap portion's rotational path is designed to clear the terminal accommodating wall during opening. This segmentation maintains stability for protection while reducing the required stroke length.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The foldable cap design reduces the necessary stroke size of the connector, allowing for a more compact configuration without compromising protection and dustproofing, enabling a smaller form factor while maintaining functionality.
Implementation Method 1
utilizing a torsion coil spring for closure
Data Source
AI summary
There is provided a connector configured by a first connector and a second connector which are fitted and electrically connected to each other. The first connector includes a projecting portion extending toward the second connector. The second connector includes: a terminal; and a cap configured to cover a front surface of the terminal and having a folding mechanism. A cover portion of the cap includes: a first cover portion provided with a rotating shaft; a second cover portion adjacent to the first cover portion and provided with a rail pin; and a connection portion that rotatably connects the first cover portion and the second cover portion to each other. The rail pin is configured to move along a rail in response to the contact portion being pressed and/or released by the projecting portion.