Spring-Supported Electrical Connector Assembly for Contact Fatigue
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current high-power transmission connectors using red copper terminals face issues with wear-out due to softness and inadequate fatigue strength, leading to instability and reduced lifespan, and existing assembly methods are complex and unreliable.
Innovation Solution
A design incorporating a spring clip with barbs and an enclosed ring to secure the contact within a base, simplifying assembly and ensuring stable positioning, while providing elastic support to enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If red copper terminals are used to improve electrical conductivity, then electrical conductivity is improved, but fatigue strength and lifespan deteriorate due to softness and wear
Solution Approach 1:
The patent uses red copper for the terminal contact portion to ensure high electrical conductivity, while employing a separate spring component made of elastic material to provide mechanical support and fatigue resistance. This composite material approach allows each material to perform its optimal function without compromising the other.
Solution Approach 2:
The patent combines the terminal and spring into an integrated contact module assembly, where the terminal is secured within the spring structure. This merging ensures that the soft terminal benefits from the spring's elastic support, distributing mechanical loads and preventing terminal deformation while maintaining electrical contact quality.
2Strength
If a spring clip is added to support the terminal, then fatigue strength is improved, but assembly complexity increases due to multiple components and steps
Solution Approach 1:
The terminal and spring are designed as an integrated contact module where the terminal fits into the spring structure with inherent positioning features. The barbs on the spring engage with corresponding features on the terminal, creating a self-aligning assembly that reduces complexity despite adding structural support.
Solution Approach 2:
The contact module is segmented into distinct functional components (terminal, spring with barbs, enclosed ring) that can be manufactured separately using optimized processes, then assembled through a simplified insertion and locking mechanism that reduces overall assembly complexity.
3Manufacturing precision
If traditional assembly methods with fixtures and heat treatment are used, then terminal positioning is achieved, but manufacturing complexity and time increase
Solution Approach 1:
The spring is pre-formed with barbs and the terminal is pre-designed with corresponding engagement features and an enclosed ring structure. This preliminary preparation of positioning features eliminates the need for complex fixtures and heat treatment during final assembly, as the components are designed to self-position and lock together.
Solution Approach 2:
The contact module assembly mechanism is designed to be self-aligning and self-locating, where the barbs on the spring automatically engage with features on the terminal during insertion. The enclosed ring structure provides inherent guidance, allowing the assembly to complete itself without external fixtures or complex positioning procedures.
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 simplified assembly process and stable structure significantly extend the plug-in lifespan of the connectors, reducing manufacturing complexity and ensuring reliable electrical contact.
Implementation Method 1
the spring may have an enclosed ring for allowing the contact to pass through... the spring can provide elastic support for the contact
Implementation Method 2
The first barb of the spring is hooked into the stop recess of the tunnel of the base for secure, and the spring may have an enclosed ring for allowing the contact to pass through
Data Source
AI summary
An electrical connector includes a base and a plurality of contact modules. The base has a plurality of tunnels. The contact modules respectively embedded in the tunnels, wherein each of the contact modules includes a contact and a spring. The spring is located in one of the tunnels and supports a contact end of the contact so that the contact end is suspended. A back end of the spring has a fixed portion having a first barb, and the first barb hooks into a stop recess of a first tube wall of one of the tunnels.