Charging Inlet Terminal Center Axis Alignment
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Solution Overview
Problem
The existing charging inlets for electric and hybrid vehicles face challenges in accurately positioning the center axis of terminals due to fit tolerance issues, leading to assembly instability and inefficiencies.
Innovation Solution
A charging inlet design featuring a terminal with a resin component having a cylindrical portion, ribs, and a flange, which is press-fitted into a housing with a press-fit hole, ensuring accurate center axis alignment and stability, combined with a terminal holder that clamps the flange to prevent terminal removal, and a production process involving cutting, insert molding, and selective plating to reduce material waste and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If terminals are integrated into the housing with conventional fitting methods, then the structure is simple and easy to manufacture, but the center axis positioning accuracy of terminals deteriorates due to fit tolerance
Solution Approach 1:
The terminal is divided into three distinct portions: a first connected portion for electrical connection, a middle portion with a resin component for positioning, and a second connected portion for wire attachment. This segmentation allows each portion to serve its specific function optimally, with the resin component acting as a dedicated positioning element that bridges the terminal and housing.
Solution Approach 2:
A resin component is introduced as an intermediary element between the terminal and the housing. This resin component includes a cylindrical portion that fits into a press-fit hole in the housing, and a flange that connects to the terminal's middle portion. The resin acts as a mediator that ensures accurate center axis positioning while accommodating fit tolerances.
2Loss of substance
If conventional cutting and shaping methods are used for terminals, then the manufacturing process is simple, but material waste increases
Solution Approach 1:
The resin component is molded in advance around the terminal's middle portion using insert molding technology. This preliminary action allows the terminal and resin component to be formed as a single integrated unit in one molding process, eliminating the need for subsequent assembly steps and reducing material waste from separate manufacturing operations.
Solution Approach 2:
The terminal structure combines metal portions (first and second connected portions) with a resin component (cylindrical portion and flange). This composite material approach allows optimal use of materials: metal for electrical conductivity and structural strength, and resin for positioning and insulation, thereby minimizing overall material waste.
3Reliability
If the terminal is secured only by clamping the flange, then the assembly is easy to manufacture, but the terminal may become loose over time
Solution Approach 1:
The terminal holder is integrated directly into the housing structure, merging the functions of the holder and housing into a single component. This integration eliminates the need for separate holder parts while maintaining the clamping function that secures the terminal flange between the holder and housing, thereby improving reliability without adding device complexity.
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 enables precise positioning of the terminal center axis with respect to the housing, stabilizes assembly, and reduces material waste and costs by minimizing unnecessary material usage during shaping and plating.
Implementation Method 1
the housing has a press fit hole in which the cylindrical portion and the ribs are press-fitted
Implementation Method 2
the flange is clamped between the housing and the holder outside the press-fit hole
Implementation Method 3
a plurality of ribs on an outer circumferential surface of the cylindrical portion, the ribs extending along an axial direction of the cylindrical portion
Data Source
AI summary
A charging inlet includes a plurality of terminals; a housing accommodating the terminals therein; and a terminal holder integrated to the housing. Each of the terminals includes: a first connected portion having a solid cylindrical shape; a second connected portion; and a middle portion. A resin component is disposed on an outer circumference of the middle portion. The resin component includes: a cylindrical portion; a plurality of ribs on an outer circumferential surface of the cylindrical portion, the ribs extending along an axial direction of the cylindrical portion; and a flange. The housing has a press-fit hole in which the cylindrical portion and the ribs are press-fitted. The flange is clamped between the housing and the terminal holder outside the press-fit hole.