Electrical Connector Insertion Assist Protrusion
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Solution Overview
Problem
Existing electrical connectors with clip contacts can experience contact failures due to insulating substances adhering to mating terminals, particularly when an insulating substrate interposes between the clip contact and the mating terminal, leading to poor connectivity.
Innovation Solution
The electrical connector employs a contact member with spring pieces that pinch the mating terminal and an insertion/extraction assist protrusion to expand the gap between these spring pieces, allowing for offset positioning to prevent interference and ensure reliable contact by wiping off insulating substances during mating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the clip contact directly contacts the mating terminal during mating, then electrical connection is established, but insulating substances may cause contact failure
Solution Approach 1:
The insertion/extraction assist protrusion performs a preliminary action by expanding the gap between spring pieces before the contact portions make contact with the mating terminal. This preliminary expansion creates space for the mating terminal to be inserted without direct contact, preventing insulating substances from causing contact failure.
Solution Approach 2:
The insertion/extraction assist protrusion acts as an intermediary element between the spring pieces and the mating terminal. It mediates the interaction by temporarily expanding the gap to allow insertion, then releasing to enable contact, thus preventing direct harmful interaction between the contact portions and insulating substances on the mating terminal.
2Reliability
If the insertion/extraction assist protrusion is positioned offset from contact portions, then interference is prevented during insertion, but the structure becomes more complex
Solution Approach 1:
The insertion/extraction assist protrusion is positioned in a different spatial dimension (offset in the width direction) relative to the contact portions. This dimensional offset allows the protrusion to expand the gap between spring pieces without interfering with the contact portions during insertion, achieving smooth insertion without increasing functional complexity.
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 design ensures reliable electrical connection by minimizing the risk of contact failures due to insulating substances, enhancing the durability and reducing the need for frequent part replacement by reducing abrasion and maintaining effective contact without sliding, thus improving the operational efficiency and cost-effectiveness of the connector.
Implementation Method 1
a contact member (80A, 80B) to be electrically connected with the fuse busbar (42, 42)
Data Source
AI summary
An electrical connector comprises a first housing, a mating terminal retained in the first housing, a second housing mated with the first housing, a contact member disposed in the second housing, and an insertion/extraction assist protrusion. The contact member is electrically connected with the mating terminal by pinching the mating terminal with a plurality of spring pieces facing each other. The spring pieces each have a contact portion protruding inward. The insertion/extraction assist protrusion is adapted to expand a gap between the spring pieces when the first housing and the second housing move relative to one another in a mating direction. The insertion/extraction assist protrusion is arranged offset from the contact portions in a plane crossing the mating direction and is arranged nearer to a start point of the mating than the contact portions during the mating in the mating direction.