Elastic Terminal Ferrule With Expansion Limit for Charging Contacts
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Solution Overview
Problem
Existing charging terminals suffer from excessive deformation and yielding when the mating terminal is inserted incorrectly, leading to unreliable electrical contact.
Innovation Solution
An elastic terminal ferrule with limit structures and mating limit structures that prevent further radial expansion when the outer diameter reaches a predetermined value, formed by an annular body with notches and protrusions that engage circumferentially to maintain optimal contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cylindrical part is designed with multiple elastic arms to improve electrical contact reliability, then the electrical contact reliability is improved, but the cylindrical part becomes susceptible to excessive deformation and yielding when incorrect insertion occurs
Solution Approach 1:
The elastic terminal ferrule is segmented into multiple elastic arms distributed in the circumferential direction, with each arm independently deformable to contact the mating terminal. This segmentation allows reliable electrical contact while distributing deformation stress across multiple independent elements rather than a single continuous structure.
Solution Approach 2:
The limit structure and mating limit structure are pre-configured on the elastic terminal ferrule to establish maximum radial expansion boundaries before any insertion occurs. These pre-set mechanical stops prevent the elastic arms from deforming beyond safe limits during incorrect insertion events, eliminating the need for post-deformation assessment.
2Adaptability or versatility
If the cylindrical part allows radial expansion to accommodate mating terminal insertion, then the mating capability is improved, but the cylindrical part may yield excessively when insertion posture is incorrect
Solution Approach 1:
The limit structure and mating limit structure create preliminary counter-action forces that oppose excessive radial expansion before it can cause yielding. When the elastic terminal ferrule encounters incorrect insertion or excessive force, these pre-positioned limit structures engage to provide immediate mechanical resistance, preventing the structural integrity from being compromised.
Solution Approach 2:
The elastic terminal ferrule utilizes parameter changes in its radial dimension, allowing controlled expansion within safe limits defined by the limit structures. The structure transitions from a rigid state to an elastically deformable state and back, with the limit structures ensuring the expansion parameter never exceeds the yield point of the material.
3Reliability
If limit structures are added to prevent excessive radial expansion, then the structural protection is improved, but the device complexity increases
Solution Approach 1:
The limit structure and mating limit structure are merged into the elastic terminal ferrule itself rather than being separate components. The limit structures are formed as integral features of the ferrule body, eliminating the need for additional separate limit-setting components and reducing overall device complexity while maintaining protective functionality.
Solution Approach 2:
The elastic terminal ferrule serves multiple functions simultaneously: it provides electrical contact through its elastic arms, limits radial expansion through its integrated limit structures, and maintains structural integrity. This multi-functionality eliminates the need for separate dedicated limit-setting components, reducing device complexity while achieving structural protection.
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 excessive radial deformation of the cylindrical part, ensuring 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 are against each other in the circumferential direction to prevent further radial expansion
Data Source
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AI summary
The present invention discloses an elastic terminal ferrule, a terminal assembly, and a charging seat. The elastic terminal ferrule comprises of an annular body (2) having two ends (211, 221) which are free in a circumferential direction of the annular body (2); a limit structure (1a, 2a) formed on the annular body (2) and near the end (211, 221) of the annular body (2); and a mating limit structure (1b, 2b) formed on the annular body (2) for mating with the limit structure (1a, 2a). When the annular body (2) is in a natural state without radial expansion, the limit structure (1a, 2a) and the mating limit structure (1b, 2b) are spaced apart from each other in the circumferential direction; when the outer diameter of the annular body (2) is expanded to a predetermined value, the limit structure (1a, 2a) and the mating limit structure (1b, 2b) are against each other in the circumferential direction to prevent further radial expansion of the elastic terminal ferrule (20). Therefore, the elastic terminal ferrule can effectively prevent excessive radial deformation of the cylindrical part of the terminal, effectively avoid yielding deformation of the cylindrical part of the terminal, and improve the service life of the terminal.