Electrical Connector Elastic Portion Stress Distribution
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Solution Overview
Problem
Existing electrical connectors with conductive contacts suffer from low stability and short service life due to the elastic deformation of a single-end connected contact portion, leading to inadequate expansion space and contact reliability.
Innovation Solution
The electrical connector features an insulative housing with multiple electrical contacts, each comprising a contacting portion, a mounting portion, and an elastic portion with two opposing elastic portions that enhance elasticity and stability by distributing stress uniformly across the contact area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-end connected elastic portion is used in the conductive contact, then the structure is simpler, but the stability and service life are reduced
Solution Approach 1:
The elastic portion is divided into a first elastic portion and a second elastic portion that are disposed on opposite sides of the contacting portion. This segmentation allows each elastic portion to independently bear and distribute stress, preventing excessive deformation at a single connection point and thereby improving stability and service life while maintaining reasonable structural complexity.
2Ease of manufacture
If a single-end connected contact portion is used, then the manufacturing is easier, but the expansion space and contact reliability are insufficient
Solution Approach 1:
The elastic portions extend in the second direction perpendicular to the first direction (length direction of contacting portion). This dimensional change from linear to perpendicular arrangement creates additional expansion space and allows the contact to reliably engage with batteries of different orientations and positions, improving contact reliability without complicating manufacturing.
3Force
If the elastic portion is elastically deformed during contact, then the contact force is generated, but the stress concentration leads to lower stability
Solution Approach 1:
The contacting portion is positioned at the center of the first and second elastic portions in the second direction, creating a symmetric local quality distribution. This arrangement ensures that stress is evenly distributed across both elastic portions during deformation, preventing stress concentration at any single point and thereby maintaining high stability while generating sufficient contact 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
This configuration significantly improves the stability and service life of the electrical connector by evenly distributing stress and ensuring a secure connection with external components, enhancing the overall reliability of the electrical connection.
Implementation Method 1
when the contacting portion is contacted to the battery, the elastic portion is elastically deformed
Data Source
AI summary
An electrical connector includes an insulative housing defining a top surface and a bottom surface opposite to each other and a plurality of electrical contacts received in the insulative housing. Each electrical contact is formed by stamping a metal plate and includes a contacting portion exposed to the top surface, a mounting portion extending out of the bottom surface and an elastic portion disposed between the contacting portion and the mounting portion and in the insulative housing, wherein the elastic portion includes a first elastic portion and a second elastic portion disposed on two opposite sides of the contacting portion.