Electrical Terminal Spring Member Design for Blade Retention

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Solution Overview

Problem

Conventional electrical terminals often require excessive force for connecting and disconnecting conductive blades, leading to potential damage due to snagging and high spring force, which complicates both insertion and removal processes.

Innovation Solution

The electrical terminal design features spring members with angled extension beams and contact ribs that distribute force evenly, reducing the likelihood of damage by minimizing sharp edges and using a deflectable housing securing member for secure snap engagement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If spring members exert high force to securely retain the blade, then the blade is securely held in place, but excessive force is required for insertion and removal and the blade may be damaged

Engineering Contradiction:

Improveblade retention securityVSAvoidblade insertion and removal ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The spring member is divided into multiple segments along its length, with each segment having a different degree of flexibility. The distal portion is more flexible while the proximal portion is more rigid, allowing the spring to exert secure retaining force while requiring less force for blade insertion and removal.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the spring member have different mechanical properties - the distal portion is designed to be more flexible to reduce insertion/removal force, while the proximal portion is more rigid to provide stable mounting and secure blade retention. This local differentiation of mechanical properties resolves the contradiction between secure retention and ease of operation.

Inventive Principle:

Principle #3Local quality

2Reliability

If the tab has a sharp edge for secure engagement with the blade opening, then the blade is securely retained, but the sharp edge may snag and damage the blade during removal

Engineering Contradiction:

Improveblade retention securityVSAvoidblade damage during removal

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Instead of having a sharp edge on the tab that protrudes outward, the tab is configured with a rounded edge that curves upward. This inverts the conventional sharp-edge design, eliminating the snagging problem while maintaining secure engagement through the curved geometry that guides the blade opening onto the tab during insertion.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The tab edge is rounded rather than sharp, and the tab itself has a curved profile. This curvature eliminates the harmful snagging effect during blade removal while maintaining secure retention through the geometric interlocking of the rounded tab with the blade opening.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Ease of manufacture

If the spring member has a straight configuration for simple manufacturing, then manufacturing is easier, but the force distribution on the blade is uneven causing potential damage

Engineering Contradiction:

Improvespring member manufacturing simplicityVSAvoidblade damage from uneven force distribution

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The spring member has an asymmetric cross-sectional configuration with different dimensions in different directions. This asymmetric design allows the spring to distribute force more evenly across the blade surface when compressed, preventing localized stress concentrations that could damage the blade, while still being manufacturable using standard spring fabrication processes.

Inventive Principle:

Principle #4Asymmetry

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 allows for easy connection and disconnection of conductive blades with reduced risk of damage, as the angled spring members and contact ribs distribute force evenly and the deflectable securing member facilitates secure mating without excessive force.

Implementation Method 1

a spring member extending from at least one of the lateral walls, the spring member configured to contact a first surface of the conductive blade

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS7255614B1Electrical terminal

Publication Date: 2007.08.14 PANCON ILLINOIS LLC

AI summary

An electrical terminal configured to electrically mate with a conductive blade may include a base integrally formed with lateral walls, at least one spring member, and at least one contact rib. The spring member extends from at least one of the lateral walls, and is configured to contact a first surface of the conductive blade. The contact rib extends from an upper surface of the base, and is configured to contact a second surface of the conductive blade. The spring member may include an extension beam angled toward the base, with a tip of the extension beam being canted away from the base, so as not to snag the conductive blade.