High-Voltage Tab Terminal Plug Assembly for Touch Protection Retention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High-voltage connectors in vehicles require a touch protection mechanism that provides a high holding force without extending onto the contact surface, and existing methods like injection molding and heat staking are costly and prone to deformation or damage.
Innovation Solution
A high-voltage tab terminal with a stud-like plug base and complementary plug socket arrangement, allowing for a high holding force without deformation, achieved through a plug assembly method that is cost-effective and secure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If injection molding is used to attach touch protection means to high-voltage contact means, then holding force is improved, but manufacturing cost increases and risk of deformation increases
Solution Approach 1:
The patent replaces the chemical/thermal bonding process (injection molding) with a purely mechanical connection system consisting of a connection element with connection protrusions that engage with receiving structures in the touch protection means and the contact means, eliminating the need for injection molding while maintaining holding force
Solution Approach 2:
The connection system is divided into separate components: a connection element distinct from both the touch protection means and the contact means, allowing for simplified manufacturing of each individual component without requiring complex integrated processes
2Force
If heat staking is used to attach touch protection means to high-voltage contact means, then holding force is improved, but risk of deformation and damage increases
Solution Approach 1:
The patent replaces the thermal bonding process (heat staking) with a purely mechanical connection system using engagement structures between the connection element, touch protection means, and contact means, eliminating thermal effects that could cause deformation or damage
Solution Approach 2:
The connection element and touch protection means are designed with self-aligning engagement structures that automatically position themselves during assembly without requiring external heating or forcing, preventing deformation through self-guided mechanical engagement
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to an electrical high-voltage tab terminal (1) for a high-voltage connector (0), preferably for a vehicle, in particular a vehicle with an electric traction motor, with an electrical high-voltage tab contact means (10) extending in the longitudinal direction (Lr) and an electrically insulating touch protection means (20) provided on a free longitudinal end portion (11) of the high-voltage tab contact means (10), wherein the high-voltage tab contact means (10) has, in its free longitudinal end portion (11), at least one stud-like plug base (110, 150) arranged in the width direction (Br) of the high-voltage tab contact means (10), and the touch protection means (20) has at least one plug socket (210, 250) which is at least partially complementary thereto, the at least one plug base (110, 150) being plugged together with the at least one plug socket (210, 250) .