Electrical Connector Containment Members for Low Resistance
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Solution Overview
Problem
Existing electrical connectors face challenges in achieving a balance between reasonable insertion force, low electrical resistance, and competitive pricing, particularly when used with aluminum or aluminum alloy cables, as they often have high electrical resistance and high manufacturing costs.
Innovation Solution
The electrical connector design incorporates flexible blades and annular compression members with angular offsets to exert centripetal radial pressure on the insertable part, reducing contact resistance and maintaining mechanical stability while being easy to manufacture and cost-effective.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If flexible blades with annular compression members are used to increase contact pressure, then insertion force is reduced, but electrical resistance increases
Solution Approach 1:
The compression member is divided into multiple independent containment members (first, second, third containment members) that can be positioned at different angular locations around the insertable part. This segmentation allows each containment member to independently apply pressure to specific regions, distributing the contact pressure more effectively across the contact interface while maintaining overall compression force, thereby reducing electrical resistance without requiring excessive insertion force.
Solution Approach 2:
Each containment member is designed with specific local characteristics including engagement portions that contact the insertable part at predetermined angular positions. The containment members can have different shapes, sizes, or material properties optimized for their specific locations. This local quality optimization ensures that pressure is applied precisely where needed to minimize contact resistance, rather than uniformly distributing pressure throughout the entire contact surface.
2Ease of manufacture
If high contact pressure is applied to compensate for small contact surface, then manufacturing cost is reduced, but resistance to vibrations and fretting increases
Solution Approach 1:
The compression member is divided into multiple independent containment members that can be positioned at different angular locations around the insertable part. This segmentation allows each containment member to independently apply pressure to specific regions, distributing the contact pressure more effectively across the contact interface while maintaining overall compression force, thereby reducing electrical resistance without requiring excessive insertion force.
Solution Approach 2:
The containment members are designed to be movable relative to the blades, allowing them to dynamically adjust their position and apply pressure in response to vibrations and mechanical stresses during operation. This dynamic adaptation enables the contact interface to maintain optimal pressure distribution under varying load conditions, improving resistance to vibrations and fretting while keeping the overall structure simple and cost-effective.
3Force
If an annular compression member in C-shape is used to increase pressure, then insertion force is reasonable, but electrical resistance remains high
Solution Approach 1:
The compression member is divided into multiple independent containment members (first, second, third containment members) that can be positioned at different angular locations around the insertable part. This segmentation allows each containment member to independently apply pressure to specific regions, distributing the contact pressure more effectively across the contact interface while maintaining overall compression force, thereby reducing electrical resistance without requiring excessive insertion force.
Solution Approach 2:
The containment members act as intermediary elements between the blades and the insertable part. Instead of the blades directly contacting and compressing the insertable part, the containment members serve as intermediate pressure application points. This intermediary mechanism allows for more precise control of pressure distribution and contact area, improving electrical contact quality while maintaining reasonable insertion force.
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 connector achieves reduced electrical resistance comparable to the cable length, easy insertion, and improved resistance to vibrations, with a simple structure that is competitively priced and easy to manufacture.
Implementation Method 1
a plurality of annular compression members 40A to 40D arranged on radially outer faces 42 of the slats 38 and each comprising a blade 58 curved around the axis of insertion D and having a C shape
Data Source
Figure 1
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AI summary
An electrical connector (1) comprising a male contact (5) and a female contact (10) movable between an uninserted position and an inserted position, wherein an insertable portion (12) of the male contact is inserted along an insertion axis (D) into a recess in the female contact (10). The female contact comprises a body (34) and a plurality of axially projecting, angularly distributed tabs (38) extending from the body, the tabs being radially flexible. The connector further comprises a plurality (40) of structurally identical annular retaining elements (40A, 40B, 40C, 40D) arranged on the tabs and adapted to exert centripetal radial pressure on the tabs. At least two of the retaining elements have distinct angular orientations relative to the body around the insertion axis.