Terminal Sensor Holder Structure for Accurate Connector Temperature Sensing

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Solution Overview

Problem

Existing connectors for electric vehicles face challenges in accurately measuring terminal temperatures using contact-type temperature sensors due to complex fixing processes and space constraints, leading to difficulties in workability and measurement accuracy.

Innovation Solution

A connector design featuring a sensor holder with a terminal mounting portion in contact with the terminal, a sensor holding portion that securely positions the temperature sensor away from the terminal, and a heat transfer portion to efficiently transfer heat from the terminal to the sensor, eliminating the need for heat shrinkable tubes and improving installation ease.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a thermistor is fixed to the terminal by collectively covering the thermistor, the terminal, and an electric wire with a heat shrinkable tube, then the temperature measurement accuracy is improved, but the workability of the fixing process deteriorates due to complexity

Engineering Contradiction:

Improvetemperature measurement accuracyVSAvoidworkability of the fixing process

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The sensor holder is divided into multiple functional portions: a terminal mounting portion for attaching to the terminal, a sensor holding portion for positioning the thermistor, and a heat transfer portion for thermal conduction. This segmentation allows each portion to be optimized independently, improving both measurement accuracy and ease of assembly without requiring complex heat shrinkable tube processes

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sensor holder acts as an intermediary component between the terminal and the thermistor. It provides a structured interface that facilitates accurate temperature measurement while simplifying the assembly process, eliminating the need for heat shrinkable tubes and improving workability

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If a non-contact-type temperature sensor is used, then the workability of the attachment work is improved, but the temperature measurement accuracy deteriorates under connector use conditions

Engineering Contradiction:

Improveworkability of the attachment workVSAvoidtemperature measurement accuracy

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The invention replaces non-contact measurement methods with a contact-type thermistor fixed to the terminal through the sensor holder. This mechanical contact ensures accurate temperature measurement under connector use conditions while maintaining improved workability through the simplified sensor holder assembly process

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If the temperature sensor is positioned in close contact with the terminal, then the temperature measurement accuracy is improved, but the space for installing the temperature sensor deteriorates

Engineering Contradiction:

Improvetemperature measurement accuracyVSAvoidspace for installing the temperature sensor

Core Design Contradiction:

Measurement precisionVSVolume of moving object

Solution Approach 1:

The sensor holder extends in the axial direction of the terminal, positioning the thermistor at a location that maintains close thermal contact with the terminal while utilizing the axial dimension for installation space. This dimensional approach resolves the conflict between measurement accuracy and installation space requirements

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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

This design enables accurate temperature measurement of the terminal while enhancing the workability of the temperature sensor attachment, allowing for better space utilization and improved measurement performance compared to traditional methods.

Implementation Method 1

a heat transfer portion that transfers heat from the terminal mounting portion to the sensor holding portion

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

a pressing portion elastically pressing the temperature sensor toward the contact surface portion

Methodology Applied

Scientific EffectElastic pressing: Elasticity

Data Source

PatentUS20240372304A1connector

Publication Date: 2024.11.07 YAZAKI CORP

AI summary

A connector includes a terminal, a terminal holder, a contact-type temperature sensor, and a sensor holder configured to hold the temperature sensor and mounted to the terminal. The sensor holder includes a terminal mounting portion that is assembled to the terminal, a sensor holding portion that holds the temperature sensor at a position not in contact with the terminal, and a heat transfer portion that transfers heat from the terminal mounting portion to the sensor holding portion.