Slit Tubular Connection Terminal for Lower-Cost EV Charging Connectors

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Solution Overview

Problem

The high manufacturing cost of connection terminals for vehicle charging connectors is a significant challenge, as conventional cutting methods are costly and inefficient.

Innovation Solution

The connection terminal features a hollow cylindrical terminal connecting portion with a first slit extending along its axis, a rectangular tube-shaped intermediate portion with a second slit, and resilient pieces that form a tubular shape, allowing for press-working and reducing manufacturing costs while increasing contact points and conductivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If cutting method is used to manufacture connection terminal, then manufacturing precision can be achieved, but manufacturing cost increases

Engineering Contradiction:

Improveconnection terminal shape precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces the cutting method with a press-working method. The connection terminal is formed by press-working a plate material into a tubular shape with slits, eliminating the need for costly cutting operations while maintaining manufacturing precision through controlled plastic deformation of the material.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If hollow cylindrical shape with slits is used, then manufacturing cost decreases, but structural strength may be reduced

Engineering Contradiction:

Improvemanufacturing costVSAvoidterminal structural strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent applies local quality by providing reinforcement portions at specific locations on the tubular connecting portion. These reinforcement portions are strategically placed to strengthen areas subjected to higher mechanical stresses while maintaining the overall hollow cylindrical structure with slits for cost-effective manufacturing.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If press-working method is used, then manufacturing cost decreases, but manufacturing precision may be affected

Engineering Contradiction:

Improvemanufacturing costVSAvoiddimensional accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent incorporates preliminary action by designing the plate material with pre-calculated dimensions and fold line positions before press-working. The slits and tubular shape are planned in advance on the flat plate, ensuring that after forming, the connection terminal achieves the required dimensional accuracy without requiring post-processing adjustments.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11862890B2Connection terminal and connector

Publication Date: 2024.01.02 SUMITOMO WIRING SYSTEMS LTD

AI summary

The present disclosure provides a connection terminal and a connector capable of suppressing an increase in manufacturing cost. A vehicle-side terminal 50 includes a terminal connecting portion 51 to be electrically connected to a charger-side terminal, a wire connecting portion 55 to be electrically connected to a wire, and an intermediate portion 56 provided between the terminal connecting portion 51 and the wire connecting portion 55. The terminal connecting portion 51 has a hollow cylindrical shape. The terminal connecting portion 51 includes a first slit 52X, 53X extending over an entire length in an axial direction of the terminal connecting portion 51. The intermediate portion 56 has a rectangular tube shape. The intermediate portion 56 includes a second slit 56X extending over an entire length in an axial direction of the intermediate portion 56.