Bent Transfer Connector for Compact High-Current Charging Sockets
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Solution Overview
Problem
In the field of power transmission, there is a need for a mechanism that allows for non-axial or angled connections between terminals and cables, as existing solutions result in bulky devices and excessive copper material usage, leading to increased costs and inefficiencies.
Innovation Solution
A transfer mechanism comprising a power transmission portion and a transfer portion with a bent section, allowing for connections at different axial directions and angles, utilizing various welding and joining methods, and made from materials like nickel, cadmium, and copper alloys, with coatings for improved conductivity and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If high current charging is implemented to reduce charging time, then charging speed is improved, but the charging socket and cable become bulky and heavy
Solution Approach 1:
The charging system is divided into separate functional components: a power transmission portion with plug-in end and connection end, and a cable portion with conductor. This segmentation allows the charging socket to be smaller and lighter while maintaining high current transmission capability through the dedicated cable infrastructure.
Solution Approach 2:
The patent introduces a transfer portion with bent zones that enables angular and spatial flexibility in connecting the cable to the terminal. This dimensional transformation allows the charging socket to be compact while the cable can be routed at various angles to reach the power source, separating the size constraints from the functional requirements.
2Adaptability or versatility
If the connection position of the cable is far from the terminal position, then flexibility is improved, but copper material consumption increases and cost increases
Solution Approach 1:
A transfer portion acts as an intermediary component between the cable's connection end and the terminal. This transfer portion includes a bent zone that allows angular deviation and spatial separation without requiring additional copper material in the terminal itself. The transfer portion serves as a geometric adapter that decouples the cable routing flexibility from material consumption.
Solution Approach 2:
The patent applies different material and structural characteristics to different parts of the system. The terminal is made compact with reduced copper content, while the transfer portion provides the necessary geometric flexibility. This local differentiation allows flexibility to be achieved where needed (in the transfer portion) without unnecessarily increasing material consumption throughout the entire system.
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
Enables compact device designs, reduces copper material consumption, and enhances electrical and mechanical performance by allowing flexible connection methods and materials selection, while improving durability and reducing costs.
Implementation Method 1
the first end is electrically connected to the connection end, the second end is electrically connected to the conductor
Implementation Method 2
the bent portion comprises at least one bent zone... allowing for connections at different axial directions and angles
Implementation Method 3
one or more methods including resistance welding, friction welding, ultrasonic welding, arc welding, laser welding, electron beam welding, pressure diffusion welding, magnetic induction welding
Data Source
AI summary
Provided by the present disclosure are a transfer mechanism for power transmission, charging socket, and motor vehicle. The transfer mechanism for power transmission includes a power transmission portion, a transfer portion and a cable, in which the power transmission portion includes a plug-in end and a connection end which are connected in sequence. The cable includes an internal conductor and an insulation layer wrapping the conductor. The transfer portion includes a first end, a bent portion and a second end which are connected in sequence, where the first end is electrically connected to the connection end, the second end is electrically connected to the conductor on one end of the cable, and the bent portion comprises at least one bent zone. By using the transfer mechanism for power transmission of the present disclosure, a non-coaxial or angled connection can be realized between a terminal and the cable, and the copper material used by the terminal can be saved to reduce the cost of the terminal.