Crown Spring Connector Assembly for Low-Resistance High-Current Contact
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Solution Overview
Problem
Contact resistances between conductive elements in electrical connectors cause temperature rise and reduce the service life of the connectors.
Innovation Solution
The electrical connector assembly features a receptacle connector with a housing and conductive terminals having crown spring portions and extending portions, allowing for a plug connector to be inserted and contact the contact arms, reducing contact resistance and increasing pluggable times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional conductive elements are used in electrical connectors, then the structure is simple, but contact resistance increases causing temperature rise and reduced service life
Solution Approach 1:
The conductive terminal is divided into multiple functional segments: a body portion, a crown spring portion with multiple contact arms, and extending portions. This segmentation allows each part to perform its specific function optimally, with the crown spring portion providing multiple contact points to distribute current and reduce contact resistance, thereby preventing temperature rise and extending service life.
Solution Approach 2:
The crown spring portion is designed with elastic deformation capability, allowing it to dynamically adapt to the plug connector during insertion and maintain reliable electrical contact. The spring portion can deform elastically to accommodate manufacturing tolerances and wear, ensuring consistent low contact resistance throughout the connector's service life, thus preventing temperature rise.
2Power
If multiple conductive elements are used for current transmission, then current carrying capacity increases, but contact resistance between elements causes temperature rise
Solution Approach 1:
The crown spring portion integrates multiple contact arms into a single unified structure that simultaneously contacts multiple corresponding arms of the plug connector. This merging of multiple contact functions into one integrated component ensures consistent electrical connection across all contact points, enabling high current carrying capacity while maintaining low overall contact resistance and preventing temperature rise.
3Ease of operation
If the connector structure is simplified, then manufacturing is easier, but the number of pluggable times is reduced
Solution Approach 1:
The crown spring portion acts as a flexible elastic component that can repeatedly deform during insertion and removal cycles. This flexibility allows the connector to accommodate repeated plugging and unplugging operations while maintaining reliable electrical contact, significantly increasing the number of pluggable times without requiring complex mechanical structures.
4Reliability
If conventional terminals are used, then device complexity is low, but contact resistance increases reducing electrical connectivity
Solution Approach 1:
The crown spring portion extends in multiple spatial dimensions with multiple contact arms arranged to correspond with multiple arms of the plug connector. This multi-dimensional arrangement ensures comprehensive electrical contact across all necessary connection points, maximizing electrical connectivity and reliability while the integrated design keeps the overall structural complexity manageable.
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 design enables high-current carrying capacity with reduced contact resistance and extended service life by integrating the crown spring portions within the through hole, enhancing electrical connectivity and durability.
Implementation Method 1
The crown spring portion includes a plurality of contact arms. The first extending portion includes a plurality of first pins. The crown spring portion is located in the first through hole. The first pins are exposed from the housing. The plug connector is inserted into the first through hole and contacts the contact arms.
Data Source
AI summary
An electrical connector assembly is provided. The electrical connector assembly includes a receptacle connector and a plug connector. The receptacle connector includes a housing and at least one electrically conductive terminal. The housing has a first through hole. The at least one electrically conductive terminal is disposed in the housing. The at least one electrically conductive terminal includes a crown spring portion and a first extending portion. The first extending portion is connected to the crown spring portion. The crown spring portion includes a plurality of contact arms. The first extending portion includes a plurality of first pins. The crown spring portion is located in the first through hole, and the first pins are exposed from the housing. The plug connector is inserted into the first through hole and contacts the contact arms.