Conductive Terminal Arc Contacts for Vibration-Stable Connectors
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Solution Overview
Problem
Power connector assemblies suffer from wear and reduced current-carrying performance due to high-frequency vibrations causing adapter springs and plug terminals to rub, leading to safety hazards.
Innovation Solution
Incorporation of first and second elastic pieces with arc-shaped contact portions on the mating portions of conductive terminals, eliminating the need for an adapter spring, enhancing structural reliability and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an adapter spring is used to connect the plug terminal and receptacle terminal, then the connection is established, but high-frequency vibrations cause repeated rubbing leading to wear and reduced current-carrying performance
Solution Approach 1:
The patent combines the adapter spring and receptacle terminal into an integrated conductive terminal structure. The elastic piece is directly formed as part of the terminal body with a unified manufacturing process, eliminating the gap and relative motion between separate components. This merging eliminates the rubbing and wear that occurred between the adapter spring and plug terminal in the prior art, while maintaining reliable electrical connection.
2Ease of manufacture
If there is a gap between the adapter spring and receptacle terminal, then assembly is simplified, but high-frequency vibrations cause repeated rubbing and wear
Solution Approach 1:
The patent integrates the elastic piece and terminal body into a single component manufactured as one piece. This eliminates the gap between previously separate components (adapter spring and receptacle terminal) while maintaining assembly simplicity through the integrated design. The unified structure prevents relative motion and rubbing during vibration, solving the reliability issue without complicating the manufacturing process.
3Reliability
If elastic contact portions with arc-shaped surfaces are used, then contact reliability is improved and wear is reduced, but the device structure becomes more complex
Solution Approach 1:
The patent integrates the elastic piece with arc-shaped contact portions directly into the terminal body as a unified component. This merging approach achieves the benefits of elastic contact (improved reliability and reduced wear) while avoiding the complexity of assembling separate elastic components. The arc-shaped surfaces are formed as integral features of the single-piece terminal structure.
Solution Approach 2:
The patent changes the geometric parameters of the contact surface by introducing arc-shaped surfaces instead of flat surfaces. This parameter change improves contact stability and distributes contact pressure more evenly, reducing wear. The arc-shaped geometry is achieved through the integrated manufacturing process of the elastic piece, maintaining structural simplicity while enhancing performance.
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 elastic contact portions improve contact reliability and reduce wear, maintaining high current-carrying performance and safety by stabilizing the connection under vibration.
Implementation Method 1
the first elastic piece includes a first elastic contact portion protruding from the first fixing portion along the first direction; the second elastic piece includes a second elastic contact portion protruding from the second fixing portion along the first direction
Data Source
AI summary
A conductive terminal includes a first fixing portion, a first mating portion, a second fixing portion and a second mating portion. The second mating portion and the first mating portion are arranged side by side along a first direction. The first mating portion includes a first elastic piece extending along a second direction. The first elastic piece includes a first elastic contact portion. The second mating portion includes a second elastic piece. The second elastic piece includes a second elastic contact portion. The first elastic contact portion extends along a first arc-shaped surface. The second elastic contact portion extends along a second arc-shaped surface. Protruding directions of the first arc-shaped surface and the second arc-shaped surface are opposite to each other along the first direction. An electrical connector and an electrical connector assembly having the conductive terminal are disclosed.