90° Elbow Plug Terminal to Cut Heat Rise and Misinsertion
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Solution Overview
Problem
Existing energy storage high-voltage connectors face issues such as high temperature rise due to increased contact resistance, high production costs, poor concentricity leading to assembly problems, and inability to prevent wrong electrode insertions while allowing 360-degree rotation.
Innovation Solution
A 90° elbow plug terminal formed by bending a single pipe with a continuous flat pipe section, integrated anti-contact pointer and housing, and a fool-proof mechanism with aligned through slots and convex rings to prevent wrong insertions and allow 360-degree rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If two pipes with different diameters are riveted to form a 90° elbow, then the plug terminal can be formed, but the contact resistance increases and temperature rise occurs
Solution Approach 1:
The patent merges two separate pipes into a single pipe structure. The plug terminal is formed by bending a single pipe at 90 degrees and pressing a flat section, eliminating the riveted connection between two pipes. This integration removes the contact resistance issue at the joint while maintaining the required 90° elbow geometry.
2Shape
If two pipes with different diameters are riveted, then the plug terminal can be formed, but the processing cost increases
Solution Approach 1:
The patent combines the manufacturing process into a single pipe that is bent and pressed into the final 90° elbow shape with a flat section, eliminating the need to purchase, cut, and rivet two separate pipes. This simplifies the manufacturing process and reduces processing costs.
3Ease of manufacture
If anti-contact pointer and shell are separate injection-molded parts, then they can be assembled, but the machining and assembly accuracy requirements increase
Solution Approach 1:
The patent integrates the anti-contact pointer and shell into a single injection-molded part. The pointer is formed as an integral component of the shell, eliminating assembly requirements and ensuring perfect concentricity without the need for high machining and assembly accuracy.
4Ease of manufacture
If anti-contact pointer and shell are separate parts, then they can be assembled, but the production cost increases
Solution Approach 1:
The patent combines the anti-contact pointer and shell into a single injection-molded component, eliminating the need for separate molding operations and assembly processes. This integration reduces production costs by streamlining manufacturing into one operation.
5Device complexity
If plug-in pipe body and wiring pipe body are interconnected, then the structure is simplified, but water vapor can enter and oxidize the wire conductor
Solution Approach 1:
The patent divides the pipe structure into separate sections: the plug-in pipe body and wiring pipe body are disconnected. A flat pressed section creates a barrier that prevents water vapor from traveling along the pipe interior to the wire conductor, while the overall structure remains simplified.
6Reliability
If bumps and chutes are added to prevent wrong insertion, then the fool-proof function is achieved, but the plug cannot rotate after insertion
Solution Approach 1:
The patent uses an asymmetric flat pressed section on the pipe that provides fool-proof functionality by preventing wrong insertions through its directional geometry, while maintaining rotational capability. The asymmetric feature guides correct insertion orientation but does not restrict rotation after insertion, unlike symmetric bump-and-chute mechanisms.
Data Source
AI summary
The present disclosure provides a plug terminal, a plug and an energy storage high-voltage connector and solves the problems that after the existing plug terminal is used, the temperature rise is too high after passing through a large current and the processing cost is too high. According to the present disclosure, the plug terminal is arranged as a 90° elbow formed by bending the middle section of a single pipe, comprising a plug-in pipe body, a flat pipe section and a wiring pipe body which are connected in sequence; the axis of the plug-in pipe body is intersected with and is perpendicular to the axis of the wiring pipe body; and the flat pipe section is arranged as a continuous flat pipe structure formed by pressing some pipe sections of the single pipe.