Electrical Connector Assembly with Multi-Oriented Contact Spring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing right-angled electrical connector assemblies require a mating axis orthogonal to the longitudinal axis of the female terminal, limiting flexibility in terminal orientation and potentially increasing wear during mating/unmating cycles.
Innovation Solution
An electrical connector assembly featuring a contact spring and retainer system that exerts a normal force between terminals, allowing for a mating axis that can be parallel or perpendicular to the longitudinal axis, with a cantilevered plate and arcuate fixed beam configuration secured by J-shaped tabs, enabling secure contact in various orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a right-angled orientation is used between male and female terminals, then compact packaging is enabled, but the mating axis must be orthogonal to the longitudinal axis of the female terminal, limiting flexibility in terminal orientation
Solution Approach 1:
The contact spring and retainer assembly is designed to accommodate both right-angled and straight orientations of the male terminal relative to the female terminal. The spring can exert normal force in different directions depending on the terminal orientation, making the connector assembly universal for multiple mating configurations without requiring different components for each orientation.
2Reliability
If a traditional spring and retainer arrangement is used, then secure electrical connection is achieved, but wear during mating/unmating cycles increases
Solution Approach 1:
The contact spring features a curved or arcuate geometry that allows it to flex and exert normal force on the male terminal during mating and unmating cycles. This curved design distributes mechanical stress more evenly across the contact surfaces, reducing localized wear and extending the service life of the connector assembly while maintaining secure electrical connection.
3Adaptability or versatility
If the contact spring is designed for multi-orientation capability, then adaptability is improved, but the device complexity increases
Solution Approach 1:
The contact spring is divided into distinct functional segments: a curved contact portion that exerts normal force on the male terminal, a retainer engagement portion that secures the spring to the retainer assembly, and intermediate flexural portions that provide the necessary compliance. This segmentation allows each portion to be optimized for its specific function while working together to achieve multi-orientation capability without excessive overall 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 allows for secure electrical connections in both right-angled and straight configurations, reducing wear and enabling compact packaging, while allowing the use of materials prioritizing mechanical properties over conductivity for the retainer and spring.
Implementation Method 1
a contact spring configured to exert a normal force between the terminal and the mating terminal when the mating terminal is arranged between the contact spring and the connection end
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An electrical connector assembly (100) includes an elongate planar terminal (104) extending along a first longitudinal axis (X) having a connection end (110) configured to interconnect the terminal (104) to a corresponding elongate planar mating terminal (204) extending along a second axis and an attachment end (112) configured to attach the terminal (104) to an electrical conductor. The electrical connector assembly (100) also includes a contact spring (116) configured to exert a normal force between the terminal (104) and the mating terminal (204) when the mating terminal (204) is arranged between the contact spring (116) and the connection end (110) such that second axis is parallel to the first axis (X) or when the mating terminal (204) is arranged between the contact spring (116) and the connection end (110) such that the second axis is perpendicular to the first axis (X).