Elastic Terminal Ferrule With Expansion Limit for Stable Charging Contact
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Solution Overview
Problem
Existing charging terminals with multiple elastic arms are prone to radial deformation and yield when the mating terminal is inserted incorrectly, leading to unreliable electrical contact.
Innovation Solution
An elastic terminal ferrule with an annular body and limit structures that prevent excessive radial expansion by abutting against each other when the outer diameter reaches a predetermined value, ensuring reliable electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple axial extension slots are formed on the cylindrical part to create elastic arms, then electrical contact reliability is improved, but radial deformation and yielding occur when insertion posture is incorrect
Solution Approach 1:
The cylindrical part is divided into multiple elastic arms through axial extension slots, allowing each arm to independently contact the mating terminal. This segmentation improves electrical contact reliability while distributing the mechanical stress across multiple independent elements, preventing catastrophic radial yielding when insertion is incorrect.
Solution Approach 2:
The patent modifies the physical parameters of the elastic arms by controlling the number, position, and dimensions of axial extension slots. This creates elastic arms with optimized flexibility and contact pressure, ensuring reliable electrical contact while maintaining sufficient radial stability to prevent yielding under incorrect insertion conditions.
2Reliability
If the cylindrical part is made more flexible to ensure electrical contact, then contact reliability improves, but the terminal fails when excessive deformation occurs
Solution Approach 1:
The elastic arms are designed to be dynamically flexible during normal operation to ensure reliable electrical contact, while the overall cylindrical structure maintains static strength through its integrated construction. The axial extension slots allow controlled flexibility in the elastic arms without compromising the structural integrity and resistance to excessive radial deformation of the entire terminal.
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
Prevents radial deformation of the charging terminal, maintaining reliable electrical contact and extending the service life of the terminal.
Implementation Method 1
When the outer diameter of the annular body is expanded to a predetermined value, the limit structure and the mating limit structure abut against each other in the circumferential direction to prevent further radial expansion of the elastic terminal ferrule
Data Source
AI summary
An elastic terminal ferrule includes an annular body, a limit structure formed on the annular body, and a mating limit structure formed on the annular body for mating with the limit structure. When the annular body is in a natural state without radial expansion, the limit structure and the mating limit structure are spaced apart from each other in a circumferential direction. When the outer diameter of the annular body is expanded to a predetermined value, the limit structure and the mating limit structure abut against each other in the circumferential direction to prevent further radial expansion of the elastic terminal ferrule.