Tuning Fork Electrical Contact with Asymmetric Prongs
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Solution Overview
Problem
Conventional planar tuning fork-type terminals are heavy and costly, requiring a significant amount of material for fabrication, which increases the mass of vehicles and hinders fuel economy, while maintaining electrical and mechanical performance is essential.
Innovation Solution
The design features a pair of prongs with a non-rectangular cross-section area, stamped from a metal sheet and folded to create a gap for mating blade terminals, reducing material thickness and weight by 40% while maintaining structural strength through a matched moment of inertia profile, and a compliant mounting tail for secure PCB insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional planar tuning fork-type terminals with rectangular cross-section are used, then structural strength and electrical performance are maintained, but mass and fabrication cost increase
Solution Approach 1:
The patent applies asymmetry by changing the prong cross-section from a symmetric rectangular shape to an asymmetric shape with a first dimension and a second dimension that is less than the first dimension. This asymmetric geometry reduces material usage and mass while maintaining structural strength through optimized dimensional proportions. The asymmetric cross-section allows the electrical contact to achieve the required moment of inertia with less material, directly resolving the contradiction between mass reduction and strength maintenance.
Solution Approach 2:
The patent employs parameter changes by modifying the geometric parameters of theprong cross-section. Specifically, it changes from a rectangular cross-section with equal or proportional dimensions to a cross-section with a first dimension and a second dimension that is less than the first dimension. This parameter optimization allows the structure to maintain the necessary moment of inertia for structural strength while using less material, thereby reducing mass without compromising strength.
2Quantity of substance
If conventional planar tuning fork-type terminals are used, then electrical and mechanical performance is maintained, but material usage and fabrication cost increase
Solution Approach 1:
The asymmetric cross-section design optimizes material distribution, concentrating material where it is most needed for structural and electrical performance while reducing it where less is required. This asymmetric geometry maintains the necessary moment of inertia for mechanical reliability and electrical conductivity pathways while using less total material, thus resolving the contradiction between material reduction and performance maintenance.
Solution Approach 2:
By changing the cross-sectional parameters from a conventional rectangular shape to an optimized shape with a first dimension and a smaller second dimension, the patent achieves better material efficiency. This parameter optimization ensures that the electrical and mechanical performance requirements are met with reduced material quantity, directly addressing the contradiction between material usage and reliability.
3Weight of moving object
If vehicle mass is reduced through lighter electrical contacts, then fuel economy improves, but electrical and mechanical connection robustness must be maintained
Solution Approach 1:
The asymmetric cross-section of theprongs optimizes the moment of inertia, providing enhanced structural rigidity and connection robustness while using less material. This asymmetric geometry strategically places material to maximize structural efficiency, ensuring that the electrical connection remains robust despite the reduced mass, thus resolving the contradiction between vehicle mass reduction and connection reliability.
Solution Approach 2:
The optimized cross-sectional parameters, with a first dimension and a second dimension that is less than the first dimension, are designed to maintain the necessary moment of inertia for robust electrical and mechanical connections. This parameter optimization allows the electrical contact to contribute to vehicle mass reduction while preserving connection robustness, directly addressing the contradiction between mass reduction and reliability maintenance.
Data Source
AI summary
An electrical contact includes a pair of prongs that extend from a base of the electrical contact spaced apart by a gap disposed therebetween. The gap is configured to receive a mating electrical contact that mechanically and electrically communicates with the pair of prongs. A plane defined along respective exterior surfaces of the pair of prongs is such that a portion of one prong of the pair of prongs is bisected by the plane. A method of making an electrical contact includes a step of stamping out a piece from a sheet of electrically-conducting material and another step of folding one or more portions of the piece to at least produce the pair of prongs of the electrical contact spaced apart by the gap. An electrical assembly includes a printed circuit board and at least one electrical contact that contains the pair of prongs.