Two-Stage Connector Insert for Terminal Realignment and Low Resistance
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Solution Overview
Problem
Repetitive connection and disconnection cycles in connector systems lead to deformation of female terminals, resulting in inconsistent contact resistance and potential overheating due to misalignment and oxide buildup, which can cause disastrous consequences like melting or burning.
Innovation Solution
The connector system incorporates a three-stage insertion process with a cover and insert mechanism, featuring tapered portions to ensure correct alignment and compression of female terminals, preventing deformation and ensuring consistent low resistance connections, and includes a self-healing feature to correct terminal alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If connectors undergo repetitive connection and disconnection cycles, then the connector system can be used multiple times, but the female terminals deform resulting in inconsistent contact resistance and potential overheating
Solution Approach 1:
The patent applies preliminary action by incorporating tapered portions on the insert that preemptively correct female terminal alignment during the insertion process. Before the connector reaches full operation, the tapered geometry proactively realigns deformed terminals, preventing the accumulation of misalignment that would lead to inconsistent contact resistance and overheating in subsequent cycles.
2Reliability
If female terminals are compressed to ensure contact, then electrical connection is established, but terminal deformation occurs leading to misalignment and oxide buildup
Solution Approach 1:
The patent employs curvature by designing tapered portions on the insert with gradual angular slopes. These curved/tapered surfaces distribute the compression force applied to female terminals during insertion, preventing concentrated stress that would cause sharp bends or misalignment. The gradual taper geometry ensures terminals are compressed into electrical contact while maintaining their structural integrity and alignment.
3Reliability
If terminal compression is increased to reduce contact resistance, then electrical connection improves, but heat generation increases risking melting or burning
Solution Approach 1:
The patent applies dynamics by designing the tapered portions to provide progressive compression rather than static fixed-force contact. As the insert is pushed into the cover during insertion, the tapered geometry dynamically adjusts the compression force applied to female terminals, ensuring adequate contact pressure for low resistance while avoiding excessive force that would generate dangerous heat. The dynamic insertion process allows controlled force application.
Data Source
AI summary
A connector includes a receptacle and a plug. The receptacle includes a first terminal of a first gender. The plug includes a second terminal of a second gender opposite to the first gender. The plug further includes a cover and an insert. The cover plugs into the receptacle. The insert includes the second terminal. The insert inserts into the cover such that the first terminal makes an electrical connection with the second terminal.