Corrugated Electrical Terminal for High-Current Connector Stability
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Solution Overview
Problem
Electrical connector assemblies face issues with undesirable dimensional changes and increased force requirements when conducting high currents, due to heat generation affecting the performance of the electrical terminal.
Innovation Solution
The electrical terminal features a receptacle portion and a spring portion with corrugated intermediate sections, providing a stable and conductive structure that maintains low force requirements during high-current conduction by utilizing alternating raised and lowered regions for multiple point contact, reducing resistance and heat-induced dimensional changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the electrical terminal conducts relatively high magnitudes of currents, then the electrical terminal can provide sufficient power transmission, but heat generated causes undesirable dimensional changes in the electrical terminal
Solution Approach 1:
The patent applies parameter changes by modifying the physical and material properties of the electrical terminal. Specifically, it changes the cross-sectional area distribution along the terminal length, introduces corrugated structures with specific geometric parameters, and selects materials with appropriate thermal and electrical conductivity parameters. These parameter modifications enable the terminal to handle high currents while maintaining dimensional stability through optimized heat distribution and structural rigidity.
2Power
If the electrical terminal conducts relatively high magnitudes of currents, then the electrical terminal can provide sufficient power transmission, but the amount of force needed to connect the electrical terminal increases
Solution Approach 1:
The patent applies local quality by creating non-uniform structural characteristics at specific locations along the electrical terminal. The corrugated intermediate portion introduces localized geometric features with varying cross-sectional areas, while the engagement arm incorporates specific surface geometries. These localized structural modifications optimize both current carrying capacity and connection force requirements without uniformly increasing terminal dimensions throughout.
3Power
If the electrical terminal structure is modified to conduct high currents, then power transmission capability is improved, but the device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the electrical terminal into distinct functional portions: a receptacle portion, an intermediate portion with corrugated structure, and an engagement arm. This segmentation allows each portion to be optimized for its specific function while maintaining overall structural coherence. The modular design facilitates manufacturing and assembly while achieving the desired high current transmission capability without excessive overall complexity.
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
The solution effectively stabilizes the resistance and force needed for terminal connection, ensuring reliable performance even with high-magnitude currents, while maintaining mechanical and electrical integrity.
Implementation Method 1
the heat generated by such relatively high-magnitude currents may cause undesirable dimensional changes in the electrical terminal
Implementation Method 2
The spring portion includes a first end portion, a second end portion, and an intermediate portion extending between the first end portion and the second end portion. The intermediate portion includes a corrugation having alternating raised and lowered regions
Implementation Method 3
The electrical terminal includes a receptacle portion and a spring portion. The receptacle portion is formed from an electrically conductive material
Implementation Method 4
The intermediate portion includes a corrugation having alternating raised and lowered regions between the first and second end portions
Data Source
AI summary
An electrical terminal for use in an electrical connector assembly includes a receptacle portion and a spring portion. The receptacle portion is formed from an electrically conductive material and includes an engagement arm having a support surface that defines a receptacle space. The spring portion is supported on the support surface of the engagement arm of the receptacle portion and is formed from an electrically conductive material. The spring portion includes a first end portion, a second end portion, and an intermediate portion extending between the first end portion and the second end portion. The intermediate portion includes a corrugation having alternating raised and lowered regions between the first and second end portions.