High-Voltage Shielded Connector Assembly With Plastic Housing

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Solution Overview

Problem

Conventional high-voltage connectors for electric vehicles face issues of bulky size, complex assembly processes, high costs, and limited suitability for mass production, particularly in the context of new energy vehicles requiring low-cost, high-productivity, and small-volume solutions.

Innovation Solution

A high-voltage shielded connector assembly featuring a plastic material design with a double-layer locking structure, integrated shield layer, and simplified assembly process, including a socket sheath body, pin, and fastening clip, which ensures reliable connection, reduced size, and enhanced shielding through a zigzag structure and foolproof mechanisms.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional high-voltage connectors use metal materials and aviation type design, then strength and vibration resistance are improved, but processing time increases, consistency deteriorates, and manufacturing cost increases

Engineering Contradiction:

ImprovestrengthVSAvoidprocessing time

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent replaces expensive metal materials with plastic materials for the connector housing, achieving cost reduction and improved manufacturability while maintaining functional requirements through engineered plastic components with integrated features

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent integrates multiple functions into the plastic housing including mounting plates, locking mechanisms, shielding layers, and sealing features, reducing the need for separate metal components and assembly steps while maintaining structural integrity

Inventive Principle:

Principle #5Merging (Combining)

2Strength

If conventional high-voltage connectors use metal materials and aviation type design, then strength and vibration resistance are improved, but manufacturing cost increases

Engineering Contradiction:

ImprovestrengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent uses composite plastic materials and integrated design combining multiple functions (structural support, shielding, sealing, locking) into single molded components, reducing assembly complexity and manufacturing cost while maintaining required strength and performance

Inventive Principle:

Principle #40Composite materials

3Stability of the object's composition

If conventional high-voltage connectors are designed with large volume, then structural integrity is improved, but assembly complexity increases and productivity decreases

Engineering Contradiction:

Improvestructural integrityVSAvoidassembly process

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses modular design with separate plug and socket halves that can be independently manufactured and then assembled, simplifying the overall assembly process while maintaining structural integrity through precise mating features

Inventive Principle:

Principle #1Segmentation

4Ease of manufacture

If conventional high-voltage connectors use plastic materials, then cost and production efficiency are improved, but size increases and assembly complexity increases

Engineering Contradiction:

Improveproduction efficiencyVSAvoidsize

Core Design Contradiction:

Ease of manufactureVSVolume of moving object

Solution Approach 1:

The patent integrates shielding layers, sealing features, and structural elements into the plastic housing to reduce overall size while maintaining production efficiency benefits of plastic material

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent nests the shielding layer and sealing elements within the plastic housing structure, achieving compact size while maintaining the advantages of plastic material manufacturing

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS10826240B2High-voltage shielded connector assembly

Publication Date: 2020.11.03 HENAN THB ELECTRIC

AI summary

Disclosed is a high-voltage shielded connector assembly. The technical problem to be solved is that existing high-voltage connectors are large in volume, complex to assemble and machine, non-universal, and high in cost. The present invention comprises a socket protection sleeve body, a pin, a socket shielding layer fixed on the socket protection sleeve body and a fixing clip fixing the socket shielding layer, wherein the pin cooperates with the socket protection sleeve body; and the pin comprises a two-layer locking structure formed by a main locking structure and an auxiliary locking structure. After using the above-mentioned technical solution, the present invention uses a high-voltage large-current plate-end shielded connector which is made of plastic and is suitable for new energy automobiles, is low in cost, has high production efficiency, is small in volume, and is simple in wiring harness assembly and processing.