Shielded Connector Cap Structure for Electric Shock Prevention
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Solution Overview
Problem
Existing electric shock prevention structures for high-voltage connectors, such as those used in hybrid or electric vehicles, are complex and require improvement for simplicity.
Innovation Solution
A connector design featuring a housing with a flat plate terminal, a metal shield member, and a protection cap with a front covering portion and locking mechanism, which covers the terminal's front end and is fixed to the shield member, preventing accidental contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a moving plate structure is used for electric shock prevention, then worker safety is improved, but device complexity increases
Solution Approach 1:
The patent extracts the essential protective function from the complex moving plate structure and implements it through a simple protection cap that covers only the necessary exposed portions of the terminal. This extraction principle simplifies the structure while maintaining electric shock prevention effectiveness.
Solution Approach 2:
The protection cap is divided into multiple segments including a front covering portion and side covering portions, each serving specific protective functions. This segmentation allows the structure to be simple yet comprehensive in protecting different exposed areas of the terminal.
2Reliability
If a protection cap is added to cover the terminal, then electric shock prevention is improved, but device complexity increases
Solution Approach 1:
The protection cap integrates multiple protective functions into a single component that combines the front covering portion and side covering portions. This merging principle reduces the number of separate parts while maintaining comprehensive protection against electric shock.
Solution Approach 2:
The protection cap serves multiple functions simultaneously: it covers the front end of the terminal, covers the side ends of the terminal, and provides a locking mechanism for secure attachment. This multi-functionality reduces the need for additional separate components.
3Reliability
If the protection cap covers the terminal, then worker safety is improved, but ease of operation decreases
Solution Approach 1:
The protection cap incorporates a movable locking mechanism that can be easily engaged and disengaged. The locking portion can move between locked and unlocked positions, allowing workers to quickly secure or remove the protection cap during connector coupling operations.
Solution Approach 2:
The locking mechanism is designed to be self-locking, where the locking portion automatically secures the protection cap to the terminal when engaged. This self-service feature reduces the complexity of operation while maintaining secure protection during use.
Data Source
AI summary
A connector includes terminals and shield members respectively supported in a housing, and protection caps. The terminal is in the form of a flat plate extending in an assembling direction D with a mating connector and has a contact point with a mating terminal of the mating connector on a plate surface of the terminal. The shield member surrounds the terminal to face the terminal in a direction orthogonal to the assembling direction D. The protection cap includes a front covering portion for covering a front end part in the assembling direction D of the terminal and locking claws locked to the shield member, and is fixed to the shield member by locking of the locking claws. The connector 10 is coupled to the mating connector with the protection caps fixed to the shield members and front end parts of the terminals covered by the front covering portions.