Electrical Connector Recess Structure for Low-Impedance Multi-Point Contact
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Solution Overview
Problem
Traditional electrical connection assemblies experience high contact impedance due to point-contact terminals, leading to reduced power density and efficiency, safety issues from temperature rise, and potential structural damage from increased clamping force.
Innovation Solution
The electrical connection assembly features a first connector with contact parts that form multi-point contact with recessed terminals in a second connector, increasing contact area without raising clamping force, thereby reducing contact impedance and preventing temperature and structural issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If point-contact terminals are used in traditional electrical connectors, then the device complexity is reduced and ease of manufacture is improved, but contact impedance increases leading to reduced power density and efficiency
Solution Approach 1:
The terminal contact surface is segmented into multiple contact points through recesses formed in the terminal body. Instead of a single point contact, the recess structure creates multiple discrete contact areas where the contact portion interfaces with the terminal, effectively segmenting the contact interface to reduce overall contact impedance while maintaining manufacturing simplicity
Solution Approach 2:
The recess structure introduces a dimensional change by creating an inwardly recessed geometry from the terminal surface. This dimensional feature transforms a potential single-point contact into a multi-point contact arrangement, increasing the effective contact area and reducing contact impedance without complicating the manufacturing process
2Loss of energy
If clamping force is increased to reduce contact impedance, then contact area increases and contact impedance decreases, but stress on contact portions increases leading to structural damage or material fatigue
Solution Approach 1:
The recess structure segments the contact interface into multiple smaller contact areas. This segmentation distributes the clamping force across multiple contact points rather than concentrating it at a single point, reducing the stress on individual contact portions while maintaining adequate total contact area to reduce contact impedance
Solution Approach 2:
The recess geometry changes the contact parameters by increasing the effective contact area without requiring increased clamping force. The inwardly recessed structure creates a geometry that naturally increases contact area, allowing the same clamping force to produce better contact performance or enabling reduced clamping force for the same contact impedance level
3Loss of energy
If high clamping force is applied to increase contact area, then contact impedance is reduced, but temperature rise causes terminals to exceed material temperature tolerance
Solution Approach 1:
The recess structure segments the contact interface to create multiple contact areas, which distributes current flow and reduces localized heating. This segmentation approach reduces contact impedance while preventing excessive temperature rise at any single contact point, keeping terminal temperatures within material tolerance
4Loss of energy
If contact area is increased to reduce contact impedance, then power density and efficiency are enhanced, but device complexity increases
Solution Approach 1:
The recess structure achieves increased contact area through a simple segmentation approach where recesses are formed in the terminal body. This segmentation creates multiple contact points without requiring complex external structures or additional components, thereby reducing contact impedance while minimizing increases in device complexity
Solution Approach 2:
The recess structure nests the contact portions within the terminal body by forming inwardly recessed geometries. This nesting approach increases the effective contact area by utilizing the terminal's own structure rather than adding external features, reducing contact impedance while avoiding significant increases in device complexity
Data Source
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AI summary
The present disclosure provides an electrical connection assembly including a first electrical connector (1, 1a) and a second electrical connector (2, 2a). The first electrical connector (1, 1a) includes a first terminal (11). The first terminal (11) includes a contact part (111a). The second electrical connector (2, 2a) is configured to pluggably connect with the first electrical connector (1, 1a), and includes a second terminal (21). The second terminal (21) includes a recess (211). The recess (211) is inwardly recessed from a surface (210) of the second terminal (21) and includes a connection section (213) and a bottom (212). The connection section (213) is in connection between the bottom (212) and the surface (210) of the second terminal (21), and includes a plurality of contact portions (215). The contact part (111a) of the first terminal (11) is in connection with the recess (211) of the second terminal (21), and the contact part (111a) of the first terminal (11) is in contact with the bottom (212) and the contact portions (215) of the recess (211) of the second terminal (21) to form a multi-points contact.