Sliding Device Connector Resolves Thermal Stress
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Solution Overview
Problem
Conventional device connectors for electric vehicles and hybrid vehicles face high production costs due to the use of aluminum die cast metal plates, and suffer from crack formation and adhesion issues between synthetic resin and metal components due to thermal expansion differences, leading to potential water ingress and reduced durability.
Innovation Solution
A device connector design featuring a metal plate with a sliding fixing portion that accommodates the shrinkage of synthetic resin, preventing stress and crack formation, while exposing the metal plate's outer edge and using a packing with annular lips for sealing, reducing production costs and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If aluminum die cast metal plate is used, then sufficient strength is provided, but production cost increases
Solution Approach 1:
The patent replaces expensive aluminum die cast metal plates with cheaper press-worked metal flat plate materials. Although press-worked plates may have slightly different mechanical properties, they provide sufficient strength for the application while significantly reducing production cost through more economical manufacturing processes.
2Stability of the object's composition
If housing shrinks more than metal plate during cooling, then thermal contraction occurs, but crack formation and adhesion loss result
Solution Approach 1:
The patent introduces a sliding mechanism between the housing and metal plate that allows relative movement during thermal contraction. The housing can slide along the metal plate surface in the radial direction, dynamically accommodating dimensional changes due to temperature variations without generating harmful stresses that would cause cracking or adhesion failure.
Solution Approach 2:
The patent changes the friction parameter at the interface between housing and metal plate by providing a sliding portion with reduced friction characteristics. This parameter change enables the housing to slide easily during thermal contraction, preventing stress accumulation and crack formation while maintaining reliable connection.
3Stability of the object's composition
If flange covers outer peripheral portion of metal plate, then housing stability improves, but shrinkage prevention in opening fails
Solution Approach 1:
The patent segments the housing structure into different functional portions: a flange portion that covers the outer peripheral area for stability, and an opening portion with a sliding mechanism that allows controlled movement. This segmentation enables the stable areas to remain fixed while the opening area can accommodate shrinkage through sliding, preventing crack formation at the opening boundaries.
4Ease of manufacture
If metal plate is pressed and formed, then production cost reduces, but structural strength may decrease
Solution Approach 1:
The patent creates a composite structure combining the press-worked metal plate with the molded housing. The metal plate provides the base structural support at low cost, while the housing material reinforces the overall assembly. This composite approach compensates for any strength reduction in the press-worked metal plate, achieving sufficient structural strength through material combination rather than relying solely on the metal plate properties.
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 solution effectively reduces production costs and prevents crack formation and water ingress, ensuring reliable sealing and durability without the need for thick metal plates, even under thermal shock conditions.
Implementation Method 1
Synthetic resin shrinks more than metal at the time of cooling. However, unlike a conventional way of preventing the shrinkage of the housing more than the metal plate, the first side sliding portion of the fixing portion is caused to slide relative to the first surface side of the metal plate and the second side sliding portion is caused to slide relative to the second surface side of the metal plate as the housing shrinks.
Implementation Method 2
Metal and synthetic resin have very different coefficients of thermal expansion and, hence, the housing shrinks more than the metal plate in a cooling process after molding.
Data Source
AI summary
A terminal block includes a metal plate (30) with an opening (31) penetrating in a plate thickness direction of the plate material and to be attached and fixed to the motor case. A housing (50) made of synthetic resin is fixed to the metal plate (30). Conductive plates (10) are held in the housing (50) while penetrating through the opening (30). The housing (50) includes a flange (52) that covers an edge of the opening (31) while exposing an outer peripheral edge portion of the metal plate (30). The flange (52) includes a wire-side flange (52A) slidable relative to the upper surface of the metal plate (30), a device-side flange (52B) slidable relative to the lower surface of the metal plate (30) and a coupling (52C) arranged in the opening (31) and coupling the both flanges (52A, 52B).