Connector Spring Biasing for Angular Error Absorption
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Solution Overview
Problem
Conventional connectors face issues with angular errors between male and female terminals due to manufacturing tolerances and abrasion of spring members, leading to poor contact pressure and workability over prolonged use.
Innovation Solution
A connector design featuring terminal units with a cylindrical plug cap and a contact that includes spring members to absorb angular errors, maintaining electric connection and preventing direct contact with the counterpart connector, thus reducing abrasion and deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If spring members are used in female electrodes to absorb angular error, then angular error absorption capability is improved, but the spring members undergo abrasion and deformation during prolonged use, reducing absorption capability
Solution Approach 1:
The connector is divided into separate components: a plug connector with male terminals and a receiving connector with female electrodes. The contact member is further segmented into a first contact portion (rigid, in the plug connector) and a second contact portion (flexible, in the receiving connector), allowing each segment to perform its specific function optimally without compromising the other.
Solution Approach 2:
The second contact portion is designed as a flexible member that can dynamically adjust its position and shape to absorb angular errors between the plug connector and receiving connector. This dynamic flexibility allows the connector to maintain reliable electrical contact even when misalignment occurs, while the rigid first contact portion maintains structural integrity.
2Ease of manufacture
If male terminals are directly inserted into female electrodes, then connection is simple, but abrasion and deformation of spring members occur during prolonged use
Solution Approach 1:
A contact member is introduced as an intermediary element between the male terminal and the female electrode. This contact member includes a first contact portion that contacts the male terminal and a second contact portion that contacts the female electrode. The contact member acts as a mediator that protects the spring member from direct abrasion while maintaining electrical connection, thereby improving durability without complicating the connection process.
3Reliability
If spring members are used to maintain contact pressure, then contact reliability is improved, but the spring members deform over time, reducing contact pressure
Solution Approach 1:
The contact system is segmented into a rigid first contact portion and a flexible second contact portion. The rigid first contact portion maintains structural stability and does not deform over time, while the flexible second contact portion maintains contact pressure through its elastic properties. This segmentation allows the system to maintain reliable contact pressure throughout its service life without the degradation issues associated with single-material spring members.
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
The connector effectively absorbs angular errors and maintains reliable contact pressure and area over extended use, enhancing workability and durability.
Implementation Method 1
at least either the first connecting portion or the second connecting portion is a spring member that movably biases the plug cap in a perpendicular direction to a fitting direction with the counterpart connector
Implementation Method 2
the spring member that movably biases the plug cap in a perpendicular direction to a fitting direction with the counterpart connector in a state in which electric connection to the terminal main body is maintained
Data Source
AI summary
A connector includes a plurality of terminal units. The terminal unit includes a terminal main body, a plug cap having the terminal main body inserted therein, fitted with a counterpart connector, and formed in a cylindrical shape, and a contact passing between the terminal main body and the plug cap. The contact includes a first connecting portion having a first abutting portion abutting on an outer circumferential surface of the terminal main body and a second connecting portion having a second abutting portion abutting on an inner circumferential surface of the plug cap. At least either the first connecting portion or the second connecting portion is a spring member movably biasing the plug cap in a perpendicular direction to a fitting direction with the counterpart connector in a state in which electric connection to the terminal main body is maintained.