Electrical Connector Terminal Retention via Rotational Insertion
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Solution Overview
Problem
Conventional double-sided compressed electrical connectors face deformation issues due to stress from conductive terminals, which can lead to unstable electrical connections, as the fixing structures like bars interfere with the connector body, causing cumulative stress.
Innovation Solution
An electrical connector design featuring a conductive terminal limited between a protruding block and a platform, with elastic arms and arc-shaped sections that reduce stress on the body by allowing the terminal to be securely positioned without direct interference, using a method that involves assembling the terminal with a strip and rotating it counterclockwise to secure it in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a fixing structure such as a barb is formed at an edge of the conductive terminal by stamping, then the conductive terminal can be fixed in the body through mass production, but the fixing structure interferes with the body to retain the conductive terminal, causing stress accumulation and body deformation
Solution Approach 1:
The patent removes the traditional barb fixing structure from the conductive terminal edge. Instead, the conductive terminal is fixed by inserting it into the accommodating hole and rotating it counterclockwise by 45 degrees, allowing the terminal to be retained without interfering fixing structures that cause stress accumulation.
Solution Approach 2:
The patent introduces a dynamic assembly process where the conductive terminal is rotated counterclockwise by 45 degrees after insertion. This rotational movement transforms the static insertion process into a dynamic one, enabling the terminal to be securely retained without requiring interfering fixing structures like barbs.
2Strength
If a barb fixing structure is used to secure the conductive terminal, then the terminal can be firmly fixed, but the barb gets stuck into the walls of the accommodating hole, applying stress to the body
Solution Approach 1:
The patent converts the potential harm of a tight fit into a benefit by designing the conductive terminal with specific dimensional parameters. The terminal's width and height are controlled to ensure it fits tightly in the accommodating hole without exceeding the wall thickness, transforming what could be a harmful interference into a beneficial secure fit without stress concentration.
Solution Approach 2:
The patent specifies precise dimensional parameters for the conductive terminal: the width W1 satisfies 0.95L1 < W1 < L1, and the height H1 satisfies 0.95L2 < H1 < L2, where L1 and L2 are the width and height of the accommodating hole respectively. These parameter controls ensure the terminal fits securely without causing harmful stress concentration in the body walls.
3Productivity
If a large quantity of conductive terminals are provided with barb fixing structures, then mass production is facilitated, but the stresses from multiple barbs are superimposed and amplified, causing body deformation
Solution Approach 1:
The patent removes the barb fixing structure entirely, eliminating the source of stress accumulation that occurs when multiple terminals are installed. The new retention mechanism based on rotational insertion does not create interfering fixing structures, allowing multiple terminals to be assembled without superimposed stresses that would cause body deformation.
Solution Approach 2:
The patent incorporates a preliminary rotational movement of 45 degrees as part of the insertion process. This preliminary action of rotating the terminal counterclockwise during insertion ensures proper positioning and retention without requiring subsequent fixing operations that would create stress concentrations.
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 design minimizes stress on the connector body, preventing deformation and ensuring stable electrical connections by distributing the force effectively and enhancing the assembly process with reduced interference and increased elasticity.
Implementation Method 1
the lower section of the first branch is limited between the first protruding block and the platform
Implementation Method 2
the conductive terminal has a base which is bending, the base bends to form an accommodating space opening forward
Implementation Method 3
the connecting section is arc-shaped, and a rear edge of the first protruding block is arc-shaped to match with the connecting section and to limit the conductive terminal from moving forward
Data Source
AI summary
An electrical connector includes a body having an accommodating hole. The body has a protruding block and a platform protruding into the accommodating hole. The platform is located below the protruding block. A conductive terminal is accommodated in the accommodating hole. The conductive terminal has a base, which bends to form an accommodating space to accommodate the protruding block. The base has a through slot, and first and second branches located at two sides of the through slot. A lower section of the first branch is limited between the first protruding block and the platform. A method for manufacturing the electrical connector includes inserting the conductive terminal with the accommodating space opening upward into the accommodating hole by the strip, and rotating the conductive terminal with the protruding block as an axis, until the lower section of the first branch is located between the platform and the first protruding block.