Multi-Point Connector Terminal Geometry for Lower Insertion Force
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Solution Overview
Problem
Conventional connector assemblies require high insertion and separation forces due to multi-contact point structures, leading to potential damage from friction and impact, especially when connecting or disconnecting plugs with numerous terminals.
Innovation Solution
A connector terminal design featuring inclined and curved contact surfaces with varying angles and support structures to reduce friction and minimize damage, allowing for easier insertion and separation while maintaining electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multi-contact point structure is adopted to ensure electrical connection, then reliability of electrical connection is improved, but insertion force increases
Solution Approach 1:
The contact portion is divided into multiple contact points (first contact point and second contact point) that contact the counterpart at different positions and angles. This segmentation allows the electrical connection function to be distributed across multiple points, ensuring reliability while each individual contact point can be designed to minimize friction during insertion.
Solution Approach 2:
Different contact points are designed with different local characteristics - the first contact point has a first inclined surface with a specific angle range (10-45 degrees), while the second contact point has a second inclined surface with a different angle range (5-30 degrees). This local quality differentiation allows each contact point to optimize for its specific function: reliable electrical contact while reducing overall insertion force through varied friction characteristics.
2Reliability
If a multi-contact point structure is adopted to ensure electrical connection, then reliability of electrical connection is improved, but separation force increases
Solution Approach 1:
The contact portion is segmented into multiple contact points with different inclined surfaces. During separation, these segmented contact points can be designed to release in a sequence or with different force requirements, allowing the connection to be reliable during operation but easier to separate when needed, by distributing the separation force across multiple points rather than requiring simultaneous overcoming of all contact forces.
Solution Approach 2:
The inclined surfaces are designed with angles that facilitate easier separation than uniform perpendicular contacts would provide. By having the contact surfaces inclined at specific angles (10-45 degrees for first contact point, 5-30 degrees for second contact point), the normal force has a component that aids separation, effectively inverting the typical friction-resistance model to allow controlled ease of separation while maintaining connection reliability.
3Ease of manufacture
If conventional connector terminal structure is used, then manufacturing simplicity is maintained, but damage to terminal and counterpart occurs during coupling and separation
Solution Approach 1:
The contact portion is designed with specific local geometric qualities - inclined surfaces with controlled angles, rounded contact points, and specific surface profiles. These local quality features are designed to reduce impact during coupling by distributing the force over a longer engagement distance, and to minimize friction damage during separation. The first inclined surface (10-45 degrees) and second inclined surface (5-30 degrees) create a gradual engagement that reduces shock loading compared to conventional sharp-edged contacts.
Solution Approach 2:
The inclined surfaces act as a form of beforehand cushioning by gradually bringing the contact points into engagement rather than sudden impact. The angled surfaces allow the counterpart to be gradually guided into position, cushioning the impact that would occur with direct perpendicular contact. This prior cushioning effect reduces damage to both the terminal and counterpart during the coupling process.
Data Source
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AI summary
A connector terminal according to a disclosed embodiment includes a body, a first arm extending forward from the body, a first contact portion provided on one end of the first arm, a second arm extending forward from the body and disposed at a higher level than the first arm, and a second contact portion formed on one end of the second arm and located rearward of the first contact portion, wherein the first contact portion includes a first inclined surface and a second inclined surface located rearward of the first inclined surface, and an angle between the first inclined surface and a horizontal line is greater than an angle between the second inclined surface and the horizontal line.