Shielded Bolt Connector Structure for Compact HV Sealing
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Solution Overview
Problem
Existing high-voltage bolt connectors in new energy vehicles face challenges with complex structure, large volume, and difficulties in achieving waterproof sealing, electromagnetic shielding, high-voltage interlocking, and finger protection.
Innovation Solution
A connector design comprising an outer shielding shell, inner insulation housing, electric transmission component, conductive terminal, insulation retaining body, and fastening assembly, which includes features like a simple structure, miniaturization, and functionalities for waterproof sealing, electromagnetic shielding, high-voltage interlocking, and finger protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional connector designs are used, then electrical connection function is achieved, but the structure becomes complex and volume increases
Solution Approach 1:
The patent combines multiple protective and functional components (shielding shell, insulation housing, retaining body, fastening assembly) into a single integrated connector structure. This merging approach achieves the required complex functions (waterproof sealing, electromagnetic shielding, high-voltage interlocking, finger protection) while optimizing the overall volume and simplifying the assembly process compared to using separate components.
Solution Approach 2:
The connector employs a nested structure where the inner insulation housing is positioned within the outer shielding shell, and the insulation retaining body is nested within the housing. This nesting arrangement maximizes space utilization, reduces overall connector volume, and maintains multiple protective functions simultaneously without increasing structural complexity.
2Reliability
If multiple protective functions are integrated, then safety and sealing are improved, but the structure becomes more complex
Solution Approach 1:
Each component of the connector is designed to serve multiple functions simultaneously. The outer shielding shell provides both electromagnetic shielding and structural protection, the inner insulation housing provides both insulation and structural support, and the fastening assembly provides both mechanical fastening and finger protection. This multi-functionality approach achieves high reliability without proportionally increasing structural complexity.
Solution Approach 2:
The patent merges the functions of waterproof sealing, electromagnetic shielding, insulation, and mechanical fastening into a single integrated structure. The combination of the shielding shell, insulation housing, retaining body, and fastening assembly creates a unified system that achieves all required protective functions while maintaining structural simplicity.
3Volume of moving object
If compact design is implemented, then volume is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The connector is divided into distinct modular components (shielding shell, insulation housing, retaining body, fastening assembly) that can be manufactured separately with standard precision requirements. The segmentation allows each component to be optimized for its specific function while maintaining ease of manufacturing, and the components are then assembled through simple insertion and fastening operations.
Solution Approach 2:
The nested arrangement of components (inner housing within outer shell, retaining body within housing) creates a compact structure that minimizes volume while maintaining clear assembly interfaces. The nesting design allows components to be assembled in a straightforward sequence without requiring complex alignment or high-precision machining.
Data Source
AI summary
A connector includes an outer shielding shell, an inner insulation housing, an electric transmission component, a conductive terminal, an insulation retaining body, and a fastening assembly. The outer shielding shell has a front port and a rear port opposite each other in a longitudinal direction of the outer shielding shell, and a top wall and a bottom opening opposite each other in a height direction of the outer shielding shell. An installation port is formed in the top wall. The inner insulation housing is inserted into the outer shielding shell from the rear port and has an insertion cavity in communication with the rear port, the bottom opening, and the installation port. The electric transmission component is inserted into the insertion cavity and led out from the rear port. The conductive terminal welded to a front end of the electric transmission component electrically contacts a mating terminal of a mating connector. The insulation retaining body installed in the bottom opening retains and positions the conductive terminal. The fastening assembly entering the inner insulation housing through the installation port fastens the conductive terminal to the mating terminal.