Snap-Fit High-Current Terminal Assembly for Error-Proof Mounting
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Solution Overview
Problem
Existing high current terminal assemblies for electric vehicles are complex and prone to assembly errors, posing safety risks due to potential damage and fire hazards.
Innovation Solution
A high current terminal assembly featuring a conductive conductor terminal with a non-conductive mounting module, utilizing snap-fitting structures for secure and error-proof assembly, ensuring a locking mechanism that prevents improper installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mounting methods are used for high current terminals, then the assembly provides basic electrical connection, but the assembly process becomes complex and prone to errors
Solution Approach 1:
The mounting module integrates multiple functions into a single component: the collar structure provides structural support and positioning, the insertion part guides the conductor terminal, and the snap-fitting structures provide secure attachment and locking. This merging of mounting, guiding, and locking functions into one integrated module simplifies the overall assembly process and reduces the number of separate components needed.
Solution Approach 2:
The snap-fitting structures automatically lock when the conductor terminal is inserted to the correct position, providing self-verifying assembly. The locking mechanism engages without additional tools or steps, and the design inherently prevents improper assembly through the interlocking geometry of the snap-fitting structures and conductor terminal.
2Ease of operation
If complex mounting procedures are used, then connection security can be achieved, but assembly time increases and errors become more likely
Solution Approach 1:
The mounting module is pre-configured with snap-fitting structures that are ready to engage with the conductor terminal. The collar structure and insertion part are pre-positioned to guide the terminal into the correct orientation, eliminating the need for complex alignment procedures during assembly and enabling quick, error-proof installation.
Solution Approach 2:
The snap-fitting mechanism replaces complex mechanical fastening systems such as screws, clips, or multi-step locking mechanisms. The elastic engagement of the snap-fitting structures provides secure attachment through simple elastic deformation, significantly simplifying the assembly process while maintaining strong mechanical and electrical connection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates quick, easy, and secure assembly with reduced risk of errors, providing a reliable connection and sealing, thereby enhancing safety and reducing the likelihood of accidents.
Implementation Method 1
A remote end of the insertion part in the insertion direction is provided with first snap-fitting structures engaging a second side of the housing wall opposite to the first side of the housing wall
Implementation Method 2
An O-ring to be arranged on an outer circumference of the conductor terminal
Data Source
AI summary
A high current terminal assembly including a conductor terminal arranged to be mounted in an orifice in a housing wall, and a mounting module for mounting the conductor terminal to the housing wall. The mounting module includes a collar configured to abut to a first side of the housing wall surrounding the orifice, and an insertion part inserted into the orifice of the housing wall. A remote end of the insertion part is provided with first snap-fitting structures engaging a second side of the housing wall opposite to the first side of the housing wall, and a first end of the conductor terminal is inserted into an opening of the mounting module such that engagement of first snap-fitting structures with a second side the housing wall is locked by the insertion of the first end of the conductor terminal.