Electrical Connector With Spring Member Between Terminals
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Solution Overview
Problem
Conventional compression contact electrical connectors face issues with terminal deformation under external pressure, leading to loss of resilience and ineffective contact with electronic members, and existing designs fail to provide optimal conductivity and mechanical performance.
Innovation Solution
The electrical connector features an insulative housing with first and second conducting terminals and spring members supported between them, preventing deformation and maintaining constant electrical connection, with the first terminals made of high conductivity materials like red bronze and the second terminals made of resilient materials like copper alloy, and elastomers or spring members to absorb pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conducting terminals are made of copper alloy for resilient power, then mechanical strength is improved, but electrical conductivity deteriorates (only 20-60% IACS)
Solution Approach 1:
The conducting terminal is divided into two separate components: a first conducting terminal made of high-conductivity material (red bronze, 70-80% IACS) and a second conducting terminal made of resilient material (copper alloy, phosphor bronze). These two terminals are electrically connected through a spring member, allowing each terminal to specialize in one function (conductivity or resilience) without compromise.
Solution Approach 2:
The electrical connector uses a composite structure combining different metal materials with complementary properties. The first conducting terminal uses red bronze for high conductivity, while the second conducting terminal uses copper alloy for mechanical resilience. This composite approach allows the system to achieve both high conductivity and strong resilient power that neither material could provide alone.
2Ease of operation
If contact portion is made plastically deformable for compression contact, then ease of operation is improved, but reliability deteriorates when deformed by external objects
Solution Approach 1:
The spring member provides dynamic resilience to the contact portion, allowing it to compress and rebound elastically rather than plastically. When external pressure is applied, the spring member compresses and then returns to its original shape, maintaining consistent contact force and preventing permanent deformation that would occur with purely plastic deformation materials.
Solution Approach 2:
The invention changes the material parameter from plastic deformation to elastic deformation by using spring members made of resilient materials. This parameter change allows the contact portion to maintain its shape and contact force after compression, preventing the loosening of resilience that occurs with plastic deformation while still enabling effective compression contact.
3Reliability
If spring members are used to provide resilient power, then reliability is improved, but device complexity increases due to horizontal oscillation issues
Solution Approach 1:
The second conducting terminal features asymmetric springy clamping arms with different structural characteristics. The clamping arms are designed with specific geometric asymmetry that provides vertical resilient support while inherently restraining horizontal oscillation. This asymmetric design allows the spring member to provide reliability without requiring additional complex restraint mechanisms.
Solution Approach 2:
The springy clamping arms of the second conducting terminal have localized structural features that provide different properties in different directions. The arms are designed to be more flexible in the vertical direction to provide resilient power, while having sufficient rigidity in the horizontal direction to prevent oscillation. This local quality differentiation allows the single spring member structure to address both reliability and complexity concerns.
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 constant and effective contact with electronic members by preventing terminal deformation and oscillation, while utilizing different materials for optimal conductivity and resilience, enhancing the stability and performance of the electrical connector.
Implementation Method 1
a plurality of spring members respectively mounted in the terminal slots and supported between the respective first conducting terminals and the respective second conducting terminals
Implementation Method 2
an elastomer supported between the first conducting terminal and the second conducting terminal
Data Source
AI summary
An electrical connector is disclosed to include two conducting terminals mounted in each terminal slot of the electrically insulative housing thereof and electrically coupled together for connection to a respective external electronic member, and a spring member accommodated in an accommodation space between the two conducting terminals in each terminal slot to support the associating conducting terminals against external pressure.