Rolled Charging Jack With Elastic Contact for Lower-Cost Sockets
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Solution Overview
Problem
The high manufacturing cost of existing jacks used in electric vehicle charging sockets, primarily due to machined and cold-extruded parts, hinders cost reduction in the overall socket design.
Innovation Solution
A rolled jack structure formed by rolling conductive strips, featuring a conductive strip jack body with a contact end and wire pressing end, including a supporting portion and a slender waist-shaped elastic structure, and a sheath fixed by an overhead hook structure, with features like pre-contact protruding portions, assembling barbs, and positioning protrusions to enhance connection and reduce manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If machined and cold-extruded parts are used for jack manufacturing, then manufacturing precision and structural strength are improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent changes the manufacturing method from traditional machining and cold extrusion to rolling process. The jack body is formed by rolling a conductive strip into a cylindrical shape and welding the seam, which simplifies the manufacturing process and reduces cost while maintaining sufficient structural integrity for electrical connection purposes.
Solution Approach 2:
The patent adopts a cost-effective manufacturing approach by using rolling and welding processes that are simpler and cheaper than precision machining. The jack body is formed from a conductive strip through rolling, and the seam is welded to create a durable but inexpensive structure suitable for the application.
2Reliability
If traditional jack structures are used, then connection reliability is maintained, but manufacturing cost becomes a bottleneck
Solution Approach 1:
The patent changes the manufacturing process parameters from machining/cold-extrusion to rolling and welding. This process change significantly reduces manufacturing cost while the resulting jack structure maintains reliable electrical connection through the continuous conductive strip and proper welding of the seam.
Solution Approach 2:
The patent combines multiple functions into the rolled jack body structure. The conductive strip is rolled to form both the structural body and the electrical conductor, eliminating the need for separate structural and conductive components, thereby reducing manufacturing complexity and cost.
3Ease of manufacture
If the jack body is formed by rolling conductive strip, then manufacturing cost is reduced, but structural strength may be compromised
Solution Approach 1:
The patent uses rolling to form the jack body from a conductive strip, which reduces manufacturing cost compared to machining. The rolled structure, when properly welded at the seam, provides sufficient strength for the application while maintaining electrical conductivity throughout the body.
Solution Approach 2:
The jack body is formed as a composite structure where the conductive strip is rolled and welded to create a seamless cylindrical form. The welding joint creates a continuous metal structure that restores and maintains the strength and conductivity of the rolled body.
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 rolled jack design significantly reduces manufacturing costs, enhances connection reliability, and improves insertion force and contact area while ensuring accurate positioning and temperature measurement, thus offering a cost-effective and practical solution.
Implementation Method 1
the contact end includes a supporting portion and a slender waist-shaped elastic structure located at a front end of the supporting portion
Implementation Method 2
a jack body rolled by a conductive strip, where the jack body includes a contact end at a front end and a wire pressing end at a rear end
Data Source
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AI summary
The utility model relates to a rolled jack, including a jack body rolled by a conductive strip, where the jack body includes a contact end at a front end and a wire pressing end at a rear end; and the contact end includes a supporting portion and a slender waist-shaped elastic structure located at a front end of the supporting portion. each part of the rolled jack provided by the utility model is formed by rolling, and the cost is greatly reduced compared with machining and cold extrusion. In addition, a contact portion of the utility model is further provided with the slender waist-shaped elastic structure, so that the contact stability of the jack can be effectively enhanced.