Elastic Sheet Plug-In Terminal for Low-Resistance Connections
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Solution Overview
Problem
Existing plug-in terminals experience high contact resistance and temperature rise during current conduction, leading to potential loosening and reduced service life.
Innovation Solution
A terminal design featuring a connecting portion with elastic sheets arranged circumferentially, allowing for adjustable contact area and reduced resistance, combined with a processing method that forms a conducting cylinder for enhanced contact and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional plug-in terminal with a hole structure is used, then the connection can be established, but the contact resistance is large and temperature rise occurs at the connection position
Solution Approach 1:
The conducting portion is divided into multiple elastic sheets arranged circumferentially, creating multiple contact points instead of a single contact area. This segmentation distributes the current flow across multiple paths, reducing contact resistance and heat generation at any single point while maintaining reliable electrical connection
Solution Approach 2:
The elastic sheets are designed to be deformable, allowing them to dynamically adjust their contact pressure with the mating terminal. This dynamic adjustment ensures optimal contact force is maintained during insertion and operation, improving connection reliability while controlling temperature rise through consistent contact pressure
2Duration of action of stationary object
If a traditional rigid terminal structure is used, then the structure is simple, but the connection may loosen over time and service life is reduced
Solution Approach 1:
The elastic sheets provide continuous adaptive pressure against the mating terminal, compensating for dimensional variations, thermal expansion, and mechanical wear over time. This dynamic compensation mechanism maintains reliable electrical connection throughout the terminal's service life without requiring complex adjustment mechanisms
Solution Approach 2:
The elastic properties of the sheets allow the contact parameters (pressure, contact area) to change adaptively in response to operating conditions. This parameter adjustment extends service life by maintaining optimal contact conditions while the overall terminal structure remains relatively simple
3Reliability
If the contact area is increased to reduce contact resistance, then the conductive property improves, but the device complexity increases
Solution Approach 1:
The conducting portion is segmented into multiple elastic sheets that collectively provide increased contact area through their circumferential arrangement. Each sheet contributes to the overall contact surface, achieving high conductive property while maintaining a relatively simple modular structure that is easier to manufacture than a single complex high-contact-area component
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 terminal ensures reliable mechanical connection, reduces contact resistance, minimizes temperature rise, and prolongs service life by maintaining elasticity and increasing contact area through elastic sheet expansion and contraction.
Implementation Method 1
the elastic sheets can be expanded outward due to their own elasticity, so as to be in close contact with the mating female terminal
Implementation Method 2
the elastic sheets can be contracted inward due to their own elasticity, so as to be in close contact with the mating male terminal
Data Source
AI summary
The present application provides a terminal and a processing method thereof. The terminal includes a connecting portion, a first fixing portion and a conducting portion that are connected in sequence. The connecting portion is used for being connected to a cable. The conducting portion includes a plurality of elastic sheets that are arranged at intervals in a circumferential direction. First ends of the elastic sheets are all fixedly connected to the first fixing portion, and a first groove is arranged between any two adjacent elastic sheets. The present application alleviates the technical problems of large contact resistance and high temperature rise at the connection position of the existing plug-in terminal.