Copper Blade Terminal Connector With Spring Retainer
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Solution Overview
Problem
Existing electrical connector assemblies for high current applications are inefficient in providing a robust and low resistance connection between copper blade terminals, often requiring excessive copper material and lacking cost-effective structural components.
Innovation Solution
The electrical connector assembly features a copper-based planar blade terminal with a U-shaped retainer and a resilient spring, which applies a normal force to ensure robust contact between terminals, allowing for the use of lower-cost materials like stainless steel or high-temperature polymers for structural components, reducing copper usage and increasing terminal cross-sectional area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If excessive copper material is used in existing electrical connector assemblies, then robust connection and electrical conductivity are improved, but cost and weight increase
Solution Approach 1:
The connector is divided into functional segments: copper blade terminals for electrical conduction, stainless steel structural components for mechanical strength, and polymer insulation for electrical isolation. Each material is used only where its properties are most beneficial, eliminating excessive copper usage while maintaining connection robustness.
Solution Approach 2:
The connector assembly uses composite construction combining copper (for conductivity), stainless steel (for structural integrity), and polymer materials (for insulation and housing). This multi-material approach replaces excessive copper with appropriate materials for each function, reducing overall copper usage while maintaining or improving connection quality.
2Quantity of substance
If copper material is reduced in electrical connector assemblies, then cost and weight are reduced, but connection robustness and electrical conductivity may deteriorate
Solution Approach 1:
Copper material is applied locally only at the blade terminals where electrical conductivity is critical, rather than throughout the entire connector structure. The retainer, housing, and structural components use stainless steel and polymers, concentrating copper usage where it provides maximum electrical benefit while minimizing overall quantity.
Solution Approach 2:
The patent replaces traditional all-copper mechanical structures with a hybrid system where stainless steel provides mechanical strength and structural support, allowing copper to be reduced to only the essential electrical contact elements. The polymer components provide structural housing and insulation functions previously requiring metal.
3Ease of manufacture
If lower-cost materials like stainless steel and polymers are used for structural components, then manufacturing cost is reduced, but electrical conductivity and connection quality may worsen
Solution Approach 1:
The connector is segmented into electrical conduction zones (copper blade terminals) and structural/support zones (stainless steel retainer and housing, polymer insulation). This segmentation allows lower-cost materials to be used for structural components while expensive copper is confined to only the electrical contact surfaces, achieving cost reduction without sacrificing conductivity.
Solution Approach 2:
The stainless steel retainer and housing serve multiple functions: providing structural support, electrical isolation, mechanical retention, and environmental protection. This multi-functionality allows these materials to replace copper in non-conductive roles, reducing overall copper usage while maintaining connection quality through proper material assignment.
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 provides a direct current path with reduced copper material usage, increased terminal area, and the ability to use lower-cost materials for structural components, enhancing mechanical properties while maintaining electrical conductivity.
Implementation Method 1
a resilient spring, which applies a normal force to ensure robust contact between terminals
Data Source
AI summary
An electrical connector assembly includes a planar terminal portion formed of a copper-based material having a connection end and an attachment end. The assembly also includes a U-shaped retainer portion having a first side wall attached to the connection end, a second side wall separated from and substantially parallel to the first side wall, and an end wall interconnecting the first side wall and the second side wall. The connection end is located intermediate the first side wall and the second side wall. The assembly further includes a resilient spring disposed intermediate the second side wall and the terminal portion and attached to the second side wall. The spring is configured to exert a normal connection force on the connection end and a mating connector inserted into a gap between the spring and the connection end.