EV Receptacle Connector Rough Surface Mechanical Bonding
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Solution Overview
Problem
Conventional receptacle connectors for electric vehicles suffer from insufficient waterproofness and airtightness due to thermal expansion coefficient differences between metal and non-metal materials, leading to crack generation and reduced charge efficiency.
Innovation Solution
The receptacle connector device features an insulating body made of waterproof plastic and metal conducting elements with rough surfaces formed in concentric circular grooves, increasing the contact area between the plastic and metal components to prevent cracking and ensure a firm combination, thereby enhancing waterproofness and airtightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal conducting elements and non-metal insulating body are used together, then electrical conductivity is improved, but crack generation occurs due to thermal expansion coefficient difference
Solution Approach 1:
The patent uses a composite structure combining metal conducting elements and non-metal insulating body, each material retaining its inherent properties (electrical conductivity for metal, insulation for non-metal) while working together in a unified connector system. This resolves the contradiction by allowing both materials to contribute their strengths without requiring either to compromise its fundamental properties.
Solution Approach 2:
The patent applies different surface treatments to different regions of the conducting elements. The outer surface maintains smooth finish for electrical contact, while the inner surface features rough treatment specifically at the junction with the insulating body to enhance mechanical bonding. This local differentiation allows the same component to satisfy both electrical conductivity requirements and structural integrity requirements in different regions.
2Ease of manufacture
If conventional smooth conducting elements are used, then manufacturing is simplified, but waterproofness and airtightness deteriorate due to crack generation
Solution Approach 1:
The patent applies rough surface treatment specifically to the inner surface of the conducting elements at the junction region with the insulating body, while maintaining smooth finish on the outer surface for electrical contact. This localized treatment enhances mechanical bonding and waterproofness only where needed, without complicating the overall manufacturing process or affecting electrical contact surfaces.
Solution Approach 2:
The patent changes the surface roughness parameter of the conducting elements from uniform smooth finish to a differentiated state with rough inner surface and smooth outer surface. This parameter modification enhances the mechanical interlocking with the insulating body and prevents crack propagation, thereby improving waterproofness and airtightness while maintaining manufacturing feasibility through standard surface treatment processes.
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
The enlarged contact area between the conducting elements and the insulating body effectively prevents crack generation, ensuring improved waterproofness and airtightness, which maintains charge efficiency and reliability in varying environmental temperatures.
Implementation Method 1
each of the plurality of the conducting elements forms a rough surface, thereby to enlarge contact area between the plurality of the conducting elements and the insulating body in moulding process for firm combination of plastic and metal materials
Implementation Method 2
cracks may be generated at junctions between the plurality of the conducting elements and the insulating body due to thermal expansion coefficient difference between metal and non-mental materials
Data Source
AI summary
A receptacle connector device for electrical vehicle use in accordance with the present invention is disposed at a battery terminal of an electric vehicle and is connected to a plug connector in a charging station. The receptacle connector comprises an insulating body and a plurality of conducting elements. The insulating body is made of waterproof plastic materials and the plurality of the conducting elements are made of metal materials. The insulating body has a plurality of concentric circular grooves and a transverse portion. The plurality of the conducting elements are respectively disposed in the plurality of the concentric circular grooves, characterized in that: each of the plurality of the conducting elements forms a rough surface, thereby to enlarge contact area between the plurality of the conducting elements and the insulating body in moulding process for firm combination of plastic and metal materials.