Integrated Terminal Bracket Molding for Stable Charging Port Assembly
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Solution Overview
Problem
Existing charging systems for new energy vehicles face challenges with difficult assembly, high production costs, and terminal instability due to gaps and separation from brackets, leading to system failures.
Innovation Solution
A bracket integrated with a terminal formed through integral injection molding, featuring anti-rotation portions like grooves and protrusions, ensuring firm connection and preventing axial or radial movement, thus simplifying assembly and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate brackets are provided for different cable types (power cable bracket and data cable bracket), then the securing capability for different cables is improved, but the device complexity increases
Solution Approach 1:
The patent combines separate power cable bracket and data cable bracket into a single integrated bracket structure. The bracket includes a first bracket body for securing the power cable and a second bracket body for securing the data cable, merged into one component that reduces overall device complexity while maintaining the ability to secure different cable types effectively.
Solution Approach 2:
The integrated bracket is divided into functional segments - the first bracket body portion for power cable securing and the second bracket body portion for data cable securing. Each segment can be independently configured to match specific cable types while being part of a unified structure that simplifies the overall device.
2Device complexity
If fixed bracket structures are used for all cable types, then the device complexity is reduced, but the adaptability to different cable specifications deteriorates
Solution Approach 1:
The bracket structure incorporates adjustable elements that allow it to adapt to different cable specifications. The bracket can be configured to match different cable diameters and types through adjustable positioning mechanisms, maintaining structural simplicity while providing versatility for various cable types including power cables and data cables.
Solution Approach 2:
The integrated bracket is designed as a universal component that can secure multiple types of cables (power cables, data cables, and combination cables) through a single structure. The bracket bodies are configured to accommodate different cable specifications while maintaining overall structural simplicity.
3Reliability
If multiple separate brackets are used for power cable and data cable, then the cable management is improved, but the manufacturing cost increases
Solution Approach 1:
The patent merges separate power cable bracket and data cable bracket into a single integrated bracket component. This consolidation reduces the total number of parts that need to be manufactured and assembled, lowering manufacturing costs while maintaining effective cable management through the integrated first and second bracket bodies.
Solution Approach 2:
The integrated bracket serves multiple functions - securing power cables, securing data cables, and managing combination cables - within a single manufactured component. This multi-functionality reduces the need for multiple separate parts, simplifying the manufacturing process and reducing overall production costs.
Data Source
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AI summary
Provided are a bracket integrated with a terminal, and a charging device. The bracket integrated with the terminal includes a bracket and at least one terminal, where an anti-rotation portion is disposed on the terminal and includes a first groove and/or a protrusion disposed on a side surface of the terminal, and the bracket is formed on at least part of the anti-rotation portion in an integral injection molding manner. According to the bracket integrated with the terminal provided by the present disclosure, the terminal and the bracket are integrally formed in an integral injection molding manner, such that a process of manually plugging the terminal into the bracket is omitted, and not only the yield can be improved, but also the costs can be reduced.