Bellows Terminal Reduces Insertion Force in High-Density Connectors
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Solution Overview
Problem
Pressure welding connectors face challenges with high insertion and extraction forces due to compact housing designs, making it difficult to easily attach and detach mating contacts and connectors, especially as the number of poles increases, leading to inefficiencies in high-density mounting.
Innovation Solution
The design incorporates a strip-shaped bellows terminal with a notched groove for wire insertion and an elastic piece that reduces insertion and extraction forces by allowing the mating contact to be inserted between the tip portion of the second fixing plate and the elastic piece, with a contact point portion inclined away from the second fixing plate, facilitating easier attachment and detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the housing width is made small for high-density mounting, then the mounting density is improved, but the insertion and extraction force becomes large
Solution Approach 1:
The bellows terminal incorporates a flexible, dynamically deformable structure that allows the contact to expand and contract during insertion and extraction. This dynamic capability enables the terminal to accommodate mating contacts with reduced force while maintaining compact dimensions, resolving the contradiction between high-density mounting and easy attachment/detachment
Solution Approach 2:
The bellows terminal changes its physical parameters (expansion/contraction) during operation to facilitate insertion and extraction. By varying the effective length and cross-sectional area of the bellows structure, the terminal can adapt to the mating contact while maintaining a compact overall size, thus achieving both high-density mounting and reduced insertion force
2Volume of moving object
If the distance from fixed ends of clamped pieces to contact point is made short for compact housing, then the housing size is reduced, but the insertion and extraction force increases
Solution Approach 1:
The bellows terminal provides a dynamic structure where the contact point can move relative to the fixed ends through expansion and contraction. This dynamic movement allows the contact point to be positioned closer to the fixed ends for compact housing while still enabling low-force insertion and extraction through the bellows deformation mechanism
3Quantity of substance
If the number of poles is increased for higher capacity, then the electrical capacity is improved, but the insertion and extraction force becomes greater
Solution Approach 1:
The connector is segmented into multiple independent bellows terminals, each capable of independent expansion and contraction. This segmentation allows each pole to be handled separately with reduced force, even when the total number of poles is high, thus maintaining ease of attachment and detachment while increasing electrical capacity
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
This design reduces the insertion and extraction force of mating contacts, making it easier to attach and detach connectors while allowing for a shorter pitch of concatenated contacts, enhancing assembly efficiency and increasing the number of contacts per unit length.
Implementation Method 1
an elastic piece that reduces insertion and extraction forces by allowing the mating contact to be inserted between the tip portion of the second fixing plate and the elastic piece
Data Source
AI summary
The pressure welding contact is provided with an electric wire connecting portion and a contact connecting portion. The electric wire connecting portion comprises a first fixing plate and a pressure welding piece. The pressure welding piece comprises a notched groove into which the core wire of the electric wire can be introduced. The contact connecting portion comprises a second fixing plate and an elastic piece. The second fixing plate contacts the first fixing plate. The elastic piece turns back from the base end portion of the second fixing plate. Further, the elastic piece is disposed in a state inclined upwards, towards the tip portion of the second fixing plate. The elastic piece comprises at its tip portion a contact point portion. The mating side connector can be inserted from between the second fixing plate and the elastic piece.