Unipolar HV Connector Terminal With Fool-Proof Protrusion Assembly
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Solution Overview
Problem
High-voltage connectors with unipolar terminals lack a fool-proof design, leading to a high risk of erroneous assembly, which affects the conduction effect.
Innovation Solution
A unipolar connection terminal with a columnar insertion tube featuring at least three protrusion structures arranged in a circumferential direction, including first and second fool-proof protrusions, and a crimping part to ensure accurate assembly and secure contact, integrated with an elastic structure and snap-fit elements for enhanced reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a unipolar connection terminal is used in a high-voltage connector, then the connector can be simplified for single-pole applications, but the risk of erroneous assembly increases due to lack of fool-proof design
Solution Approach 1:
The connection terminal employs asymmetric protrusion structures with different cross-sectional areas (first fool-proof protrusion with larger area, second fool-proof protrusions with smaller areas) arranged in a specific circumferential pattern. This asymmetric design creates a unique geometric signature that allows only one correct orientation during assembly, effectively preventing erroneous installation while maintaining the simplified unipolar connector structure.
2Reliability
If protrusion structures are added to the connection terminal to prevent erroneous assembly, then assembly accuracy improves, but the device complexity increases
Solution Approach 1:
The connection terminal is segmented into distinct functional regions: the columnar insertion tube for basic connection, multiple protrusion structures (first and second fool-proof protrusions) for orientation guidance, and the crimping part for mechanical securing. This segmentation allows each component to perform its specific function independently, achieving fool-proof assembly prevention without requiring a complete redesign of the entire terminal structure.
Solution Approach 2:
The protrusion structures are strategically positioned at specific locations on the insertion tube with varying cross-sectional areas. The first fool-proof protrusion has a larger cross-sectional area while the second fool-proof protrusions have smaller areas, creating local quality variations that provide directional guidance. This localized feature addition maintains the overall simplicity of the terminal while achieving the goal of preventing erroneous assembly.
3Reliability
If multiple protrusion structures with different cross-sectional areas are used, then fool-proof assembly is achieved, but manufacturing complexity increases
Solution Approach 1:
The connection terminal integrates multiple functions into a single unified structure: the insertion tube, all protrusion structures (first and second fool-proof protrusions), and the crimping part are formed as one piece. This merging approach allows the complex multi-feature terminal to be manufactured in a single molding or forming operation, reducing manufacturing steps and complexity despite the presence of multiple geometric features with different cross-sectional areas.
Data Source
AI summary
A unipolar connection terminal for a high-voltage connector and a connector device are provided in the invention. The unipolar connection terminal is mounted in a housing of the connector device. The connector device has a columnar insertion tube to be connected and passed through by a mating terminal, an end portion of the insertion tube extends in a radial direction to form at least three protrusion structures, and the at least three protrusion structures are arranged at intervals in a circumferential direction of an end surface of the insertion tube. According to the unipolar connection terminal and the connector device provided by the invention, when the unipolar connection terminal is mounted in the housing of the connector device, an erroneous assembly can be effectively avoided due to the arrangement of the protruding structures disposed at the end portion of the insertion tube, and a conduction effect of the connector device is guaranteed.