Connector Terminal Coupling Portion Aspect Ratio Design
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Solution Overview
Problem
Existing electrical connectors face challenges in miniaturization while maintaining the desired contact force due to limitations in thinning the coupling portion of connector connection terminals, which are typically manufactured by punching conductive thin plates, making it difficult to further lower the height and reduce dimensions while ensuring adequate contact force.
Innovation Solution
The connector connection terminal features a coupling portion with an aspect ratio of the cross-sectional area greater than or equal to 1.2, allowing for easier rotation and increased operational force, achieved through electroforming, which enables a miniaturized design with a lowered height while maintaining the desired contact force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the height dimension of the movable beam is reduced to minimize the connector height, then the second moment of area of the movable beam is reduced and the contact force becomes insufficient, but increasing the height dimension increases the connector height
Solution Approach 1:
The coupling portion is designed with a specific aspect ratio (width-to-height) of 1.2 or more, creating a localized structural characteristic that differs from the rest of the terminal. This local structural optimization allows the coupling portion to provide sufficient rotational support while keeping the overall terminal height minimal, resolving the contradiction between reduced height and maintained contact force capability
2Length of moving object
If the coupling portion is thinned to reduce the connector height, then the connector height is reduced, but the manufacturing precision becomes difficult to ensure due to the limits of press working
Solution Approach 1:
The aspect ratio of the coupling portion is changed to 1.2 or more, representing a parameter modification that allows the structure to achieve adequate rotational support with reduced height. This parameter change enables the coupling portion to function effectively at thinner dimensions while remaining manufacturable through conventional press working processes
3Area of stationary object
If the pitch between connector connection terminals is reduced to minimize the connector width, then the connector width is reduced, but the manufacturing precision and assembly difficulty increase
Solution Approach 1:
Instead of further reducing the pitch in the horizontal direction, the invention addresses the miniaturization need by optimizing the vertical dimension (height) of the coupling portion. This dimensional shift allows for reduced connector width without compromising terminal spacing, as the height optimization provides the necessary structural functionality at smaller overall dimensions
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 solution allows for a miniaturized connector with a lower height that ensures both the desired operation force and contact force, enhancing the connector's reliability and productivity by increasing the substantial distance between supporting points and improving rigidity.
Implementation Method 1
an elastic deformation amount in a width direction of the coupling portion is smaller than or equal to 0.05 mm when a load corresponding to 1 N is applied in a height direction of the coupling portion
Data Source
AI summary
A connector connection terminal has a fixed piece to be inserted to a base of a connector, a coupling portion extending from the fixed piece, and a movable piece extending in parallel to the fixed piece to both sides from a free end of the coupling portion and being operated by an operation lever rotatably assembled to the base. An aspect ratio of a cross-sectional area of the coupling portion is greater than or equal to 1.2.