Terminal Holder Locking Structure for EV Connector Assembly
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Solution Overview
Problem
The existing charging connectors for electric vehicles face challenges in manufacturing workability due to complex assembly processes that are prone to positional deviations of rod-shaped terminals, making the assembly process difficult and inefficient.
Innovation Solution
A connector design featuring a terminal holder with elastically displaceable locking portions that engage with rod-shaped terminals to restrict movement, and a housing with pressing portions that secure the terminals in place, eliminating the need for a rear holder and enhancing assembly ease.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rear holder is assembled to finally fix the terminals to the housing, then the terminals are securely fixed, but the assembly process becomes complex and workability deteriorates
Solution Approach 1:
The invention extracts and eliminates the rear holder component from the assembly. The terminal holder is designed to be directly mounted to the housing with locking portions that engage with the housing, removing the need for the separate rear holder assembly step while maintaining secure terminal fixation.
Solution Approach 2:
The invention merges the terminal holder mounting function directly to the housing by integrating locking portions into the terminal holder structure. This combines what were previously separate functions (terminal holding and housing mounting) into a single integrated component, simplifying the assembly process.
2Manufacturing precision
If multiple assembly steps are used to prevent positional deviation, then positioning accuracy is improved, but the number of assembly steps increases and productivity decreases
Solution Approach 1:
The terminal holder is pre-formed with locking portions that are designed to engage with corresponding features on the housing. This preliminary structuring of the locking portions allows the terminal holder to be directly and accurately mounted to the housing in a single action, eliminating the need for multiple positioning and adjustment steps.
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
This design improves manufacturing workability by preventing positional deviations and simplifying the assembly process, allowing for more efficient and accurate placement of terminals within the connector.
Implementation Method 1
the terminal holder includes a plurality of locking portions arranged in a circumferential direction of the terminal, the plurality of locking portions being elastically displaceable in a radial direction of the terminal
Implementation Method 2
the housing includes one or more first pressing portions that press the plurality of locking portions of the terminal holder inward in the radial direction
Implementation Method 3
a second pressing portion that presses the terminal inward in the radial direction
Data Source
AI summary
A connector includes a terminal, a terminal holder, and a housing. The terminal holder includes a plurality of locking portions arranged in a circumferential direction of the terminal, the plurality of locking portions being elastically displaceable in a radial direction of the terminal and being capable of engaging with the terminal to restrict movement of the terminal in the radial direction and an axial direction. The housing includes a first pressing portion that presses the plurality of locking portions inward in the radial direction, and a second pressing portion that presses the terminal inward in the radial direction.