Offset Terminal Connection Structure for Wire Pitch Flexibility
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Solution Overview
Problem
Existing terminal connection structures in vehicle charging inlets are limited by fixed inter-terminal and inter-electric wire pitch dimensions, leading to interference issues and manufacturing losses due to erroneous connections, and they fail to efficiently accommodate varying current and output requirements.
Innovation Solution
A terminal connection structure that allows individual setting of inter-terminal and inter-electric wire pitch dimensions by shifting the connection portions of the electric wire relative to the central axis of the terminal, using a housing with accommodating chambers and offset terminal members to facilitate independent adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the electric wire diameter is increased to increase current and output capacity, then the current and output capacity are improved, but the electric wires interfere with each other due to fixed inter-electric wire pitch dimension
Solution Approach 1:
The invention separates the determination of inter-terminal pitch dimension from inter-electric wire pitch dimension. The inter-terminal pitch dimension is determined by the terminal arrangement in the housing, while the inter-electric wire pitch dimension is determined by the offset distance of the electric wire connection portion from the terminal central axis. This segmentation allows independent optimization of each dimension to resolve the contradiction between wire size and interference prevention.
Solution Approach 2:
The invention introduces an offset dimension by shifting the electric wire connection portion away from the terminal central axis. This creates an additional spatial dimension for wire arrangement, allowing larger diameter wires to be accommodated without interfering with adjacent wires, thus resolving the contradiction between wire diameter and interference.
2Ease of manufacture
If the electric wire diameter is made small for small current and output, then cost is reduced, but useless space is created in the housing
Solution Approach 1:
The invention makes the system adaptable by allowing the offset distance of the electric wire connection portion to be adjusted based on the required current and output capacity. For small current applications, smaller wires can be used with appropriate offset distances, fully utilizing the housing space without creating useless voids, while maintaining cost-effectiveness.
Solution Approach 2:
The invention allows changing the offset distance parameter of the electric wire connection portion to match different wire diameters and current requirements. This parameter adjustment enables optimal space utilization whether small or large diameter wires are used, eliminating useless space while accommodating the required electrical capacity.
3Manufacturing precision
If the connection terminal structure is shifted relative to electric connection portion as in prior art, then inter-terminal and inter-electric wire pitch dimensions can be different, but erroneous connection operation occurs leading to manufacturing loss
Solution Approach 1:
The invention introduces the offset distance as an intermediary parameter that clearly defines the relationship between the terminal central axis and the electric wire connection portion. This explicit offset design, combined with the housing structure that guides wire insertion, prevents erroneous connection operations while maintaining flexible pitch dimension design, thereby improving both manufacturing precision and connection reliability.
Solution Approach 2:
The housing structure is designed with predetermined guiding features that align the electric wires with the offset connection portions before connection occurs. This preliminary alignment action prevents erroneous connections by ensuring wires are correctly positioned relative to the offset terminals, eliminating manufacturing losses while maintaining pitch flexibility.
Data Source
AI summary
A terminal connection structure includes a housing having a plurality of terminal accommodating chambers, a terminal accommodated in each of the terminal accommodating chambers, and a terminal-equipped electric wire in which a connection terminal connected to end portion of an electric wire is electrically connected to an electric wire connection portion of the terminal. A connection portion of the electric wire connection portion to which the connection terminal is connected is shifted relative to a central axis of electric connection portion of the terminal.