Conductive Terminal Stacked Contact Design
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Solution Overview
Problem
Existing conductive terminals with a double-layer structure, where the outer stainless steel terminal is shorter than the inner copper terminal, limit current carrying capacity as only the inner terminal makes electrical contact, failing to meet increasing application current demands.
Innovation Solution
A conductive terminal design featuring a first terminal with multiple contact portions and a second terminal with protrusions that extend through gaps in the first terminal, allowing simultaneous contact with a mating member and enhancing current carrying capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the outer layer terminal is made shorter than the inner layer terminal, then the clamping force is improved, but the current carrying capacity is limited
Solution Approach 1:
The patent transitions from a single-plane contact arrangement to a multi-dimensional staggered contact arrangement. The second terminal's contact portion extends through gaps between the first terminal's contact portions, creating contact points in different spatial dimensions. This allows both terminals to simultaneously contact the mating member, effectively utilizing three-dimensional space to increase current carrying capacity without compromising the clamping force provided by the shorter outer terminal design.
2Device complexity
If only the inner layer terminal makes electrical contact, then the structure is simple, but the current carrying capacity cannot meet increasing application requirements
Solution Approach 1:
The patent divides the contact function into two separate terminals (first terminal and second terminal), each with its own contact portions. The second terminal is segmented to have contact portions that extend through specific gaps between the first terminal's contact portions. This segmentation allows both terminals to independently contribute to current carrying capacity while maintaining a relatively simple overall structure that builds upon the conventional single-terminal design.
3Quantity of substance
If the second terminal contact portion extends through the gap, then simultaneous contact is enabled, but the manufacturing precision requirement increases
Solution Approach 1:
The patent employs a nested arrangement where the second terminal is positioned within or alongside the first terminal, with the second terminal's contact portions extending through gaps in the first terminal's structure. This nesting approach allows the contact portions to be pre-aligned during assembly, reducing the need for high-precision post-assembly alignment. The gaps are specifically designed to accommodate the extending contact portions, providing natural alignment references that simplify manufacturing tolerances.
Data Source
AI summary
A conductive terminal includes a first terminal and a second terminal stacked on the first terminal. The first terminal has a plurality of first contact portions at an end of the first terminal. A gap is formed between two adjacent first contact portions. The second terminal has a second contact portion at an end of the second terminal. At least a part of the second contact portion extends through the gap of the first terminal.