Female Terminal Elastic Contact Segmentation
Solution Overview
Problem
Existing female terminals face a challenge in forming a large number of elastic contact pieces without sacrificing the life of the die used for punching, as increasing the slit width to accommodate more pieces reduces the number of formable pieces.
Innovation Solution
The design incorporates first and second elastic contact pieces with spaces between them, allowing for increased formation of elastic contact pieces without die life compromise, with the second pieces disposed in the space between the first, enhancing contact area and reducing resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the width of each slit is increased to accommodate more elastic contact pieces, then the number of elastic contact pieces formable in the base material decreases, but the life of the die is extended
Solution Approach 1:
The elastic contact member is segmented into multiple elastic contact pieces by forming slits in the base material. This segmentation allows the single base material to be divided into multiple functional contact pieces that can independently deform and contact the male terminal, thereby increasing the total number of contact pieces without requiring excessive slit width that would compromise die life.
Solution Approach 2:
The invention optimizes the spatial arrangement of elastic contact pieces by considering their three-dimensional deformation characteristics. The pieces are arranged and dimensioned to utilize vertical deformation space rather than only horizontal spacing, allowing more contact pieces to be formed within the same base material area without increasing slit width beyond die capacity.
2Reliability
If more elastic contact pieces are formed to increase the contact area with the male terminal, then the insertion force increases, but electrical connection reliability improves
Solution Approach 1:
Each elastic contact piece is designed with optimized local dimensions and deformation characteristics. The pieces have specific thicknesses and lengths that allow them to deform locally with moderate force, distributing the insertion force across multiple pieces rather than concentrating it. This local optimization maintains low insertion force while ensuring reliable electrical contact through adequate contact area.
Solution Approach 2:
The elastic contact pieces are designed to dynamically deform during insertion and maintain continuous contact pressure. Their elastic properties allow them to adapt to the male terminal's position and maintain optimal contact force throughout operation, ensuring reliable electrical connection without requiring excessive insertion force to initiate contact.
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 configuration enables a higher number of elastic contact pieces, reducing resistance and insertion force, while maintaining die life, thus improving electrical connection reliability and workability.
Implementation Method 1
the elastically-deformed elastic contact pieces of the elastic contact members get into pressure contact with the male terminal due to resilience
Data Source
AI summary
An electrical connector for a male terminal to be inserted includes an elastic contact member provided in at least one of surfaces of the electrical connector extending in an insertion direction of the male terminal. The elastic contact member is configured to get into contact with the male terminal. The elastic contact member includes: first elastic contact pieces formed with a space in between in a widthwise direction orthogonal to the insertion direction, cantilevered at one end side of the at least one surface in the insertion direction, and configured to get into contact with the male terminal inserted in the electrical connector; and a second elastic contact piece disposed in the space and configured to get into contact with the male terminal inserted in the electrical connector.