Connection Terminal Plug Sealing for Latent Heat Temperature Control

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Solution Overview

Problem

Existing connectors for electric vehicles face challenges in sealing latent heat storage materials within their terminals, making it difficult to prevent temperature rises during high current charging.

Innovation Solution

A connection terminal design that includes a sealed space within the terminal housing a latent heat storage material and a gas, with a sealing hole that can be easily blocked by a plug member, allowing for efficient heat absorption and reduced thermal influence.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a heat transfer member is sealed in an enclosed space defined by a tubular portion, then temperature rise of the terminal can be effectively prevented, but the sealing process becomes difficult requiring joining operations

Engineering Contradiction:

Improvetemperature rise preventionVSAvoidsealing difficulty

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The terminal is divided into multiple portions: a tubular portion for heat transfer, a base portion for structural support, and a blocking portion for sealing. This segmentation allows each component to perform its specific function while simplifying the overall sealing process, as the blocking portion can be separately formed and then joined to the tubular portion.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The blocking portion acts as an intermediary component that facilitates sealing of the enclosed space. Instead of directly sealing the tubular portion, the blocking portion is introduced as a separate element that can be joined to the tubular portion, thereby enclosing the heat transfer member and simplifying the sealing process.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a cover is welded and fixed to block an opening of a tubular case main body, then heat storage material can be held, but the process becomes complex requiring welding

Engineering Contradiction:

Improveheat storage material retentionVSAvoidwelding process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The welding process is replaced with a mechanical joining method. The blocking portion is joined to the tubular portion through mechanical means (such as press-fitting or interference fitting) rather than thermal welding, thereby retaining the heat storage material reliably while eliminating the complexity of welding operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If current is increased to increase charging capacity and shorten charging time, then charging performance is improved, but temperature of the connector increases due to heat generation

Engineering Contradiction:

Improvecharging speedVSAvoidconnector temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The heat transfer member utilizes phase transition (latent heat absorption) to manage thermal energy. When the heat transfer member undergoes phase change, it absorbs significant heat energy without substantial temperature increase, thereby enabling high current charging while preventing excessive temperature rise in the connector.

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The heat generated by high current charging, which is normally a harmful effect, is converted into a beneficial process by using the heat transfer member to absorb this heat through phase transition. The thermal energy that would otherwise cause temperature rise is instead utilized to drive the phase change of the heat transfer member, thereby protecting the connector from overheating.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 design effectively absorbs heat generated during high current charging, preventing rapid temperature rises in the terminal and facilitating easy sealing of the latent heat storage material, improving thermal management without requiring complex welding processes.

Implementation Method 1

a latent heat storage material sealed in a sealed space defined in a holding portion provided between the terminal connecting portion and the electric wire connecting portion

Methodology Applied

Scientific EffectLatent heat: Latent Heat

Implementation Method 2

The heat storage material can absorb heat generated in the terminal. Therefore, a rapid temperature rise of the terminal can be prevented.

Methodology Applied

Scientific EffectHeat absorption: Absorption (physical)

Data Source

PatentEP4125157B1Temperature rise preventing connection terminal and method for its production.

Publication Date: 2023.11.22 YAZAKI CORP

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AI summary

A connection terminal (10) includes a terminal connecting portion (21) configured to be electrically connected to a counterpart terminal, an electric wire connecting portion (23) configured to be electrically connected to an electric wire, a holding portion (22) provided between the terminal connecting portion and the electric wire connecting portion and configured to be held by a housing, a sealed space (26) formed in the holding portion, a latent heat storage material (33) and a gas (35) sealed in the sealed space, a sealing hole (29) communicating the sealed space with a space outside the connection terminal, and a plug member (36) configured to block the sealing hole.