Crown Spring Terminal Structure for Low-Resistance Multi-Point Contact
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Solution Overview
Problem
Existing crown spring terminals in electrical connectors have limited contact points, leading to high contact resistance and insertion force, and are prone to wear and yield during multiple insertions, failing to meet the demands of high-performance and high-precision electrical equipment.
Innovation Solution
A crown spring terminal design featuring a cylindrical body with composite spring lamellae comprising simply supported and cantilever beams, annular-zone depressions for multi-point contact, and through-holes to reduce stress concentration, along with protrusions for increased contact area and improved flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional crown spring terminal with limited contact points is used, then structure is simple, but contact resistance is high and current-carrying capacity is limited
Solution Approach 1:
The spring lamella is divided into multiple independent contact points (first contact point, second contact point, third contact point) along its length, each capable of making contact with the plug pin. This segmentation increases the number of contact points from one to multiple, thereby reducing contact resistance and improving current-carrying capacity while maintaining a relatively simple overall structure
Solution Approach 2:
The invention transitions from a single contact point (zero-dimensional point contact) to multiple contact points distributed along the spring lamella (one-dimensional line contact). This dimensional change allows the contact area to extend along the length of the spring lamella, significantly increasing the effective contact area and current-carrying capacity
2Area of moving object
If traditional crown spring terminal with uniform cylindrical structure is used, then manufacturing is simple, but insertion force is large and contact area is limited
Solution Approach 1:
The spring lamella is designed with varying local properties: different widths at different positions (narrower at ends, wider in middle), different thicknesses (thinner at contact points), and varying curvature radii. These local quality variations optimize the contact area at each contact point while distributing the insertion force more evenly, reducing peak forces and improving overall performance
3Duration of action of stationary object
If traditional crown spring terminal with constant cross-section is used, then structure is simple, but service life is limited due to wear and yield at minimum inner diameter
Solution Approach 1:
The cross-sectional parameters of the spring lamella are varied along its length: width changes from narrower at ends to wider in the middle, thickness varies to be thinner at contact points, and curvature radius changes to provide better stress distribution. These parameter changes eliminate the constant minimum inner diameter that causes wear and yield, significantly extending service life
Solution Approach 2:
The spring lamella is designed with increased thickness and optimized geometry at the contact points where wear and yield are most likely to occur. This beforehand reinforcement cushions against wear and plastic deformation during repeated insertions and extractions, preventing failure at these critical locations and extending the terminal's service life
4Reliability
If traditional crown spring terminal with single contact point per lamella is used, then structure is simple, but conduction capacity is insufficient for high-performance equipment
Solution Approach 1:
Each spring lamella is segmented into multiple contact points (first, second, and third contact points) distributed along its length. This segmentation transforms a single-point contact into a multi-point contact system, increasing the effective contact area and current-carrying capacity to meet the demands of high-performance electrical equipment
Solution Approach 2:
The invention combines multiple contact points along the spring lamella into a unified contact system that works together to transmit current. The first, second, and third contact points are merged into a single continuous contact interface with the plug pin, creating a robust conduction path with distributed current flow that enhances overall conduction capacity
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
Enhances contact area and reduces contact resistance, providing a longer service life and gentler insertion force, thereby improving electrical performance and reliability.
Implementation Method 1
a plurality of spring lamellae arranged between the two connection bands and electrically connected to at least one of the two connection bands
Data Source
AI summary
The present disclosure describes a crown spring terminal, comprising: two connection bands respectively located at two ends of the crown spring terminal; and a plurality of spring lamellae arranged between the two connection bands and electrically connected to at least one of the two connection bands, wherein the plurality of spring lamellae comprise: simply supported beam and cantilever beam; and connection portion provided between at least one pair of adjacent simply supported beam and cantilever beam, to be used for providing electric connection between the at least one pair of adjacent simply supported beam and cantilever beam.