Charging Inlet Terminal Mounting for Plug Misalignment
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Solution Overview
Problem
Conventional charging inlets for electric and hybrid vehicles cannot adjust the radial position of terminals due to misalignment with charging plugs, leading to potential assembly instability and reduced electric transmission stability.
Innovation Solution
A charging inlet design featuring terminals with a rubber component on their outer circumference, integrated with a housing through insert molding, allowing for adjustable radial positioning without a terminal holder, reducing material waste and plating costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If terminals are fixed rigidly in the housing using a terminal holder, then assembly stability is improved, but adaptability to terminal misalignment deteriorates
Solution Approach 1:
The patent changes the physical state of the terminal mounting system from rigid to flexible by introducing a rubber component. The terminal is mounted on a rubber component that can elastically deform, allowing the radial position to be adjusted within the housing to accommodate misalignment with the charging plug, while still maintaining stable electric transmission.
2Reliability
If a terminal holder is used to secure terminals, then reliability of terminal fixation is improved, but device complexity increases
Solution Approach 1:
The patent merges the terminal mounting function directly into the housing structure. The housing includes an accommodating space that directly receives and secures the terminal without requiring a separate terminal holder. This integration maintains reliable terminal fixation while simplifying the overall structure by eliminating the additional component.
3Manufacturing precision
If terminals are shaped by cutting, then manufacturing precision is improved, but loss of substance increases
Solution Approach 1:
The patent changes the manufacturing method from mechanical cutting to molding. The terminal is formed by molding, which allows for precise dimensional control while minimizing material waste. The molding process creates the terminal shape directly from the material, eliminating the significant material removal that occurs with cutting operations.
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 stable electric transmission by allowing radial adjustment of terminals to accommodate misaligned charging plugs, enhancing assembly stability and reducing material usage and costs.
Implementation Method 1
a rubber component is interposed between the housing and the terminal so that the terminal is held in a displaceable manner by the housing
Implementation Method 2
a rubber component molding step of molding the rubber component by means of insert molding in which the terminal is placed in a mold for producing the rubber component
Implementation Method 3
a housing molding step of molding the housing by means of insert molding in which the terminal integrated with the rubber component is placed in a mold for producing the housing
Data Source
AI summary
A charging inlet includes: a plurality of terminals; and a housing accommodating the terminals therein. Each of the terminals includes: a first connected portion having a solid cylindrical shape; a second connected portion; and a middle portion. A rubber component is disposed on an outer circumference of the middle portion. The rubber component includes: a cylindrical portion; and a flange connected to the cylindrical portion and having a ring shape with a larger diameter than the cylindrical portion. The rubber component is embedded in the housing. The rubber components are interposed between the housing and the terminals so that the terminals are held in a displaceable manner by the housing.