Connector Guide Surface Reduces Terminal Wear
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Solution Overview
Problem
Conventional connector devices for service plugs in vehicles experience wear between first and second terminals, leading to increased contact resistance due to metal plating peeling, as the second terminal slides on the guide surface of the first terminals during connection and disconnection.
Innovation Solution
A connector device design featuring a pair of first terminals with a resin cover body that includes a guide surface for the second terminal's contact points, reducing the slide distance and wear by guiding the contact points in a direction to separate them, and incorporating a spring-biased second terminal with arms to collectively sandwich the first terminals, along with an insulating member for reduced wear and improved insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the second terminal slides on the guide surface of the first terminals during connection and disconnection, then the connector device can be easily assembled and disassembled, but wear is generated between the terminals leading to increased contact resistance
Solution Approach 1:
The patent introduces a guide surface as an intermediary element between the first and second terminals. This guide surface provides a controlled sliding path that reduces direct contact and friction between the terminal contact surfaces, thereby minimizing wear and preventing plating peeling while still enabling easy connection and disassembly operations.
Solution Approach 2:
The patent modifies the surface characteristics of the guide surface to change friction parameters. By optimizing the guide surface geometry and material properties, the sliding friction between terminals is reduced, allowing for easy assembly and disassembly without generating excessive wear that would lead to contact resistance increase.
2Reliability
If metal plating is applied to terminals to reduce contact resistance, then electrical conductivity is improved, but plating peels due to wear during repeated connection and disconnection
Solution Approach 1:
The guide surface acts as a mediator that protects the plated terminal surfaces from direct sliding contact. By providing a dedicated guidance path, the guide surface prevents the plated surfaces from experiencing the full extent of wear during assembly and disassembly, thereby preserving plating integrity and maintaining electrical conductivity over time.
Solution Approach 2:
The guide surface provides beforehand protection to the plated terminal surfaces. By establishing a controlled sliding path in advance, the guide surface cushions the plated surfaces against the harmful effects of friction and wear during repeated connection operations, preventing plating peeling before it occurs.
3Device complexity
If the guide surface is formed directly on the first terminals, then the structure is simplified, but the slide distance increases causing more wear
Solution Approach 1:
The patent transitions from forming the guide surface directly on the terminal surface (two-dimensional approach) to providing a separate guide surface structure (three-dimensional approach). This dimensional change allows for optimization of the sliding path geometry to minimize slide distance and wear, while still maintaining structural simplicity through integrated design.
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 design effectively reduces wear and contact resistance by minimizing the slide distance between the second terminal and first terminals, preventing plating peeling and ensuring reliable electrical connections while maintaining insulation and simplifying the device configuration.
Implementation Method 1
a second terminal that includes a pair of contact points electrically connected to the respective first terminals and is biased by a spring so that the contact points collectively sandwich the first terminals
Implementation Method 2
the guide surface guides the contact points in a direction for separating the contact points when the first terminals are connected to the second terminal
Data Source
AI summary
A connector device includes a pair of first terminals, a second terminal, and a cover body. The first terminals are arranged in parallel. The second terminal includes a pair of contact points that are electrically connected to the respective first terminals, and is biased by a spring so that the contact points collectively sandwich the first terminals. The cover body made of a resin is attached to tip parts of the first terminals. The cover body includes first guide surfaces that have the contact points of the second terminal sliding thereon and guide the contact points in a direction for separating the contact points when the first terminals are connected to the second terminal. Thus, wear of the first terminals and the second terminal can be reduced.