High-Current Module Connector With Integrated Latching Assembly
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Solution Overview
Problem
Existing high-current module connectors for electric vehicles require complex installation processes and may suffer from connector slippage issues, necessitating additional housing parts and precise alignment, which complicates manufacturing and assembly.
Innovation Solution
A high-current module connector design featuring a single-piece, non-conductive housing with a latching device and a threaded socket that allows quick assembly without additional housing parts, along with a touch protection sleeve for safety, and a compensation sleeve for tolerance compensation, facilitating simple and secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex installation process with additional housing parts is used, then connector stability is improved, but installation time and manufacturing complexity increase
Solution Approach 1:
The patent combines multiple housing parts into a single integrated housing structure that incorporates the latching device, feed opening, and retention features as built-in elements. This merging eliminates the need for separate installation steps involving multiple components while maintaining connector stability through the integrated design of the housing interior and latching mechanism.
2Manufacturing precision
If multiple housing parts are used, then manufacturing precision can be optimized for each part, but device complexity and assembly steps increase
Solution Approach 1:
The housing is designed as a single integrated component that combines functions previously requiring separate parts. The housing interior, feed opening, and latching device are formed as unified structures, reducing the number of parts while maintaining manufacturing precision through optimized single-piece fabrication processes.
3Ease of operation
If a two-part housing design is used, then ease of assembly is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent employs a single-piece housing design that eliminates the need for joining multiple housing parts. This integrated approach simplifies manufacturing by removing assembly steps and potential failure points while maintaining ease of operation through the built-in latching device and optimized housing geometry that guide connector insertion.
4Reliability
If additional housing parts and precise alignment features are added, then connector retention is improved, but installation complexity and time increase
Solution Approach 1:
The latching device and retention features are integrated directly into the housing structure as built-in elements rather than separate components. The housing interior geometry and latching mechanism work together as a unified system to provide connector retention, eliminating the need for additional alignment features and reducing installation complexity.
Data Source
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AI summary
The invention relates to a high-current module connector (15, 20), to a module connector system (10) and to a method for installing the high-current module connector (15, 20), wherein the high-current module connector (15, 20) has at least one electrical connector (45) with a first connector portion (60), a threaded socket (50) and a housing (40), wherein the housing (40) is designed in the manner of a hollow body and encloses a housing interior (95), wherein the housing (40) has a latching device (115), a first insertion opening (90) arranged at the end and a feed opening (100) on a housing portion (80) extending circumferentially around the installation axis (35), wherein the connector (45) traverses the first feed opening (100) in such a way that the first connector portion (60) and the threaded socket (50) arranged on the first connector portion (60) are arranged in the housing interior (95), wherein the latching device (115) is arranged at the feed opening (100), wherein the latching device (115) retains the first connector portion (60) and the threaded socket (50) in the housing interior (95) by the threaded socket (50) bearing against the latching device (115).