Charging Contact Assembly With Brush Motion Isolation
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Solution Overview
Problem
Existing charging contact systems experience shunt failure due to repeated vertical motion of brushes, leading to fatigue and eventual failure, especially in battery-powered vehicles.
Innovation Solution
A charging contact assembly design that isolates primary motion of the brush from the flexible connection, using a biasing mechanism to maintain contact with a connector surface, allowing for relative movement while minimizing strain on the flexible connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the brush is directly connected to the shunt with rigid connection, then electrical connection is stable, but the shunt experiences fatigue and failure due to repeated vertical motion
Solution Approach 1:
The patent replaces the rigid shunt connection with a flexible printed circuit board (FPC) that can accommodate the vertical motion of the brush. The FPC's flexibility allows it to bend and flex with the brush motion without experiencing the same fatigue and failure modes as rigid connections, thereby maintaining electrical connection stability while improving shunt reliability.
Solution Approach 2:
The patent transitions from a static rigid connection to a dynamic flexible connection that can adapt to motion. The FPC is designed to flex and bend in response to brush displacement, allowing the connection to dynamically accommodate vertical motion while maintaining electrical contact, thus preventing fatigue failure.
2Reliability
If the brush is allowed to move vertically to maintain contact, then electrical contact is maintained, but the flexible connection experiences strain and potential failure
Solution Approach 1:
The FPC is specifically designed with appropriate flexibility to accommodate brush motion without excessive strain. The flexible nature of the FPC allows it to bend with the brush while distributing the mechanical stress, preventing premature failure and extending the lifespan of the connection while maintaining reliable electrical contact.
Solution Approach 2:
The patent changes the mechanical parameters of the connection by using an FPC with specific flexibility characteristics. By controlling the flexibility parameter of the FPC, the system can accommodate brush motion while limiting the strain on the connection, thereby extending its operational lifespan while maintaining contact reliability.
3Duration of action of stationary object
If the brush motion is isolated from the flexible connection, then strain on the connection is reduced, but the complexity of the connection structure increases
Solution Approach 1:
The FPC serves as both the electrical connection and the motion isolation mechanism in a single integrated component. The flexible nature of the FPC inherently isolates the brush motion from the rigid circuit board while maintaining electrical connection, reducing overall system complexity compared to using separate rigid connections with additional motion isolation mechanisms.
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
Reduces strain on the flexible connection, thereby extending its lifespan and preventing shunt failure by isolating the primary motion of the brush, ensuring reliable electrical contact.
Implementation Method 1
a biasing mechanism to maintain contact with a connector surface
Data Source
AI summary
A charging contact assembly can include a brush configured to translate in a first direction generally perpendicular to a second direction of travel of the charging contact assembly. The brush can include a first contact surface for contacting the conducting surface, and a second contact surface parallel to the first direction of translation of the brush and parallel to the second direction of travel of the charging contact assembly. The charging contact assembly can also include a connector having a flexible connection, and a connector contact surface electrically coupled with the flexible connection and arranged parallel to the second contact surface of the brush to slidingly contact the second contact surface of the brush. The charging contact assembly can further include a biasing mechanism for biasing the connector contact surface of the connector into contact with the second contact surface of the brush.