Plug-In Connector Pin Structure for Sleeve Carbonization Control
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Solution Overview
Problem
High power connectors with insulating sleeves face damage and pollution issues due to carbonization and scratching when used in high-temperature environments, leading to reduced conduction efficiency.
Innovation Solution
A high power connector design featuring a pin with a guiding portion having an inclined surface and a smaller insulating sleeve that is secured on a platform, preventing direct contact with the female contact and minimizing the risk of damage and pollution by using a truncated cone shape that converges away from the pin body, reducing the likelihood of arcing and carbonization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulating sleeve is used to protect the pin during insertion, then the pin is protected from arcing damage, but the insulating sleeve may undergo carbonization and become fragile in high-temperature environments, leading to scratching and damage
Solution Approach 1:
The patent extracts the guidance function from the insulating sleeve and assigns it to a separate guiding portion on the pin body. The insulating sleeve is reduced to only its essential insulating function, preventing contact with the female contact during insertion. This separation allows the insulating sleeve to be smaller and less prone to carbonization damage while the guiding portion handles the mechanical guidance task.
Solution Approach 2:
The pin structure is segmented into distinct functional portions: a guiding portion with an inclined surface for guidance, a working portion for power transmission, and an insulating sleeve for electrical insulation. This segmentation allows each component to be optimized for its specific function, with the insulating sleeve being smaller and positioned to avoid high-temperature contact zones.
2Ease of operation
If the insulating sleeve contacts the female contact during insertion, then guidance function is performed, but carbonized particles from the insulating sleeve adhere to the female contact surface, reducing conduction efficiency
Solution Approach 1:
The guidance function is extracted from the insulating sleeve and transferred to a dedicated guiding portion made of conductive material. This allows the insulating sleeve to remain small and non-contacting, eliminating the source of carbonized particles while the guiding portion provides the necessary insertion guidance through its inclined surface geometry.
Solution Approach 2:
The guiding portion acts as an intermediary between the insulating sleeve and the female contact. It provides the mechanical guidance function that would otherwise require the insulating sleeve to contact the female contact, thereby preventing carbonized particle contamination while maintaining ease of insertion.
Data Source
AI summary
An electric plug-in connector terminal structure includes a pin and a female terminal. The pin has an insulating sleeve. The insulating sleeve is disposed at a front end of the pin. The insulating sleeve has an annular guiding slope. The annular guiding slope expands from a root of the insulating sleeve. The female contact has a guiding slope. The guiding slope is disposed at a front end of the female terminal. The guiding slope is inclined. An inclination direction of the annular guiding slope is the same as an inclination direction of the guiding slope.