Plug Adapter Assembly With Rotational Locking for Waterproof Stability
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Solution Overview
Problem
Conventional adapter assemblies for electric vehicle chargers suffer from reduced stability and waterproof capability due to loose screw fixation, which also complicates manufacturing and flexibility in production.
Innovation Solution
The adapter assembly features a casing with side walls, a front cover, and a rear cover, along with a plug adapter that uses protrusions and position-limiting portions for secure assembly, enhancing stability and waterproofing through a combination of fastening elements and rotational connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a screw is used to fix the plug adapter on the casing, then the assembly is simple, but the stability is reduced when subjected to impact
Solution Approach 1:
The fixing mechanism is segmented into multiple independent protrusions (at least two) distributed around the circumference of the plug adapter. Each protrusion engages with a corresponding groove on the casing, distributing the impact force across multiple points rather than concentrating it at a single screw location, thereby maintaining stability under impact while keeping the assembly process simple.
Solution Approach 2:
The fixing mechanism transitions from a single-point linear connection (screw) to a multi-point radial distribution around the circumference. This dimensional change from one-dimensional point fixation to two-dimensional circumferential distribution enhances stability by creating a more robust geometric configuration that resists impact forces from various directions.
2Ease of manufacture
If a screw is used to fix the plug adapter on the casing, then the assembly is simple, but the waterproof capability is reduced due to gaps
Solution Approach 1:
Instead of using a screw that penetrates from one side and leaves gaps, the design inverts the approach by using protrusions that extend outward from the plug adapter to engage with grooves on the casing. This inversion allows the protrusions to make continuous contact with the casing surface, eliminating gaps and preventing moisture infiltration while maintaining assembly simplicity.
Solution Approach 2:
The protrusions are designed with flexible characteristics, allowing them to deform slightly during assembly and maintain continuous contact with the casing grooves. This flexibility ensures that the sealing interface remains intact under various conditions, preventing moisture ingress while keeping the structure simple and easy to manufacture.
3Strength
If a screw is used to fix the plug adapter on the casing, then the connection is secure, but the application flexibility is reduced
Solution Approach 1:
The protrusion-groove fixing mechanism serves multiple functions simultaneously: it provides secure mechanical connection, enables easy assembly and disassembly, allows for different adapter configurations, and maintains waterproof sealing. This multi-functionality replaces the single-function screw connection, thereby enhancing application flexibility while maintaining connection strength.
Solution Approach 2:
The fixing mechanism transitions from a static permanent connection (screw requiring tools for removal) to a dynamic reversible connection. The protrusions can be easily inserted and removed without tools, allowing for quick changes between different adapter types and applications, thereby significantly improving application flexibility while maintaining secure connection during use.
Data Source
Figure 1
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AI summary
The present disclosure provides an adapter assembly (1). Portion of the main body (61) of the plug adapter (6) is penetrated through the opening (421) and exposed to the exterior of the accommodation space (44). Each protrusion (62) is penetrated through the concave (422) and exposed to the exterior of the accommodation space (44). Each protrusion (62) exposed to the exterior of the accommodation space (44) is connected with the position-limiting portion through the rotation of the plug adapter (6). Each fastening element (5) is plugged into the first hole (424) and the second hole (63). The plug adapter (6) is fastened to the casing through the fastening element (5) and the connection between the protrusion (62) and the position-limiting portion. The adapter assembly (1) includes two impact bearing points. One is formed by the fastening element (5), and the other is formed by the connection between the protrusion (62) and the position-limiting portion. The stability and the waterproof capability of the adapter assembly (1) are enhanced.