Terminal Wire Sensor Fixing via Segmented Shrinkable Tubes
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Solution Overview
Problem
Existing terminal fittings for electric vehicle charging connectors face issues with waterproofness and sensor positioning due to the deformation of shrinkable tubes, leading to gaps and difficulties in corrosion prevention and measurement accuracy.
Innovation Solution
A terminal equipped electric wire configuration that includes a water stop shrinkable tube covering the electric wire connection portion and a sensor fixing shrinkable tube positioned on the outer surface of the water stop tube, ensuring a watertight seal and improved sensor adhesion, with the sensor positioned on the outer surface of the water stop tube for enhanced measurement accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single shrinkable tube is used to cover both the electric wire connection portion and the sensor, then the sensor can be easily attached and the structure is simple, but the cross-sectional shape becomes deformed from circular, causing gaps and poor sealing
Solution Approach 1:
The patent divides the single shrinkable tube into two separate shrinkable tubes: a first shrinkable tube for covering the electric wire connection portion and providing waterproof sealing, and a second shrinkable tube for covering and fixing the sensor. This segmentation allows each tube to maintain its circular cross-sectional shape and perform its specific function effectively, resolving the contradiction between ease of manufacture and waterproofness.
Solution Approach 2:
The patent introduces an intermediary structure (the first shrinkable tube) between the electric wire connection portion and the sensor. This intermediary tube provides a stable circular base that maintains waterproof sealing while allowing the second shrinkable tube to properly secure the sensor without compromising the seal.
2Device complexity
If a single shrinkable tube is used to cover both the electric wire connection portion and the sensor, then the structure is simple, but it is difficult to know the fixed position of the sensor and confirm whether the sensor is at the specified position
Solution Approach 1:
By separating the covering function into two distinct shrinkable tubes, the patent enables visual differentiation of components. The first tube indicates the sealed connection area while the second tube indicates the sensor position, making it easy to verify sensor placement without increasing overall structural complexity.
Solution Approach 2:
The patent utilizes visual differentiation (analogous to color changes) by having two distinct shrinkable tubes that can be visually distinguished. This allows inspectors to easily identify the sensor position and verify correct installation through visual inspection, resolving the difficulty of detecting and measuring sensor position.
3Adaptability or versatility
If the shrinkable tube is deformed from circular shape after shrinkage, then it can cover irregular surfaces, but gaps are likely to occur between the electric wire connection portion and the shrinkable tube
Solution Approach 1:
The patent segments the sealing function from the sensor mounting function. The first shrinkable tube is dedicated to sealing the electric wire connection portion and maintains a circular shape to ensure proper sealing performance, while the second tube handles sensor mounting. This resolves the contradiction by allowing adaptability where needed without compromising sealing.
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
The configuration enhances waterproofness and holding reliability of the sensor, improving measurement accuracy and ease of inspection by maintaining a watertight seal and ensuring proper sensor positioning without gaps, thus preventing corrosion and ensuring reliable temperature detection.
Implementation Method 1
a water stop shrinkable tube covering the electric wire connection portion connected to the exposed portion in a watertight manner
Implementation Method 2
a sensor fixing shrinkable tube covering and fixing the sensor on the outer surface of the water stop shrinkable tube
Data Source
AI summary
A terminal equipped electric wire includes an electric wire including: a conductor and an insulating sheath covering the conductor, a part of the conductor extending out of an end portion of the insulating sheath being an exposed portion, a terminal fitting having an electric wire connection portion at a rear side of the terminal fitting, the electric wire connection portion being connected to the exposed portion, a water stop shrinkable tube covering the electric wire connection portion connected to the exposed portion in a watertight manner, a sensor disposed on an outer surface of the water stop shrinkable tube, the sensor contacting the outer surface of the water stop shrinkable tube and a sensor fixing shrinkable tube covering and fixing the sensor on the outer surface of the water stop shrinkable tube.