Movable Touch-Proof Power Connector With Integrated Assurance Member
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Solution Overview
Problem
Designing touch-proof elements for high-voltage power connectors in motor vehicles is complicated, especially in right-angle configurations, and requires complex manufacturing tools, which is further complicated by the need for terminal latch retention features.
Innovation Solution
The touch-proof element is manufactured independently of the housing and integrated into an existing assurance member, such as a connector position assurance (CPA) member, reducing the number of parts and assembly steps, and allowing for easier design of manufacturing tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a touch-proof element is integrated into the connector housing, then the terminal is protected against finger contact, but the manufacturing tool design becomes complicated
Solution Approach 1:
The touch-proof element is separated from the housing and integrated into the assurance member instead. This segmentation allows the housing and assurance member to be manufactured independently using separate tools, simplifying the manufacturing tool design while maintaining the touch-proof protection function.
Solution Approach 2:
The touch-proof element is merged with the assurance member (CPA or TPA member) which is already part of the connector structure. This combination eliminates the need for a separate touch-proof component while maintaining the protection function, and allows both features to be implemented in a single manufacturing process for the assurance member.
2Reliability
If multiple features (touch-proof element and terminal latch retention) are implemented in the connector, then the connector provides comprehensive protection, but the number of parts and assembly steps increases
Solution Approach 1:
The touch-proof element is merged with the assurance member, which already provides terminal latch retention functionality. By combining these features into a single component, the number of parts is reduced and assembly steps are simplified, while comprehensive protection is maintained.
Solution Approach 2:
The assurance member is designed to serve multiple functions: it provides terminal latch retention to secure the terminal in the housing, and simultaneously provides touch-proof protection by preventing finger access to the terminal. This multi-functionality eliminates the need for separate components for each function.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A power connector (3) comprising a dielectric housing (6), at least one power terminal (7) accommodated in the housing (6) and a touch-proof element (17) made providing a security protection preventing the intrusion, between the housing (6) and the touch-proof element (17), of a probe (20) the dimensions of which are predetermined by a standard, so as to prevent said at least one power terminal (7) from being brought into contact with said probe (20). The touch proof element (17) is supported by an assurance member (10) which is formed as a separate part from the housing (6) and which is movable relative to the housing (6), between a delivery position and a final position in which the connector (3) is functional.