Female Terminal Heat Reduction via Segmented Contact Design
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Solution Overview
Problem
Existing female terminals generate excessive heat due to conductor resistance when high currents flow, leading to increased processing and material costs with thicker plates to mitigate this issue.
Innovation Solution
A female terminal design with a box-shaped body open in the front-rear direction, incorporating a contact pressure applying portion and a bottom wall contact that mounts the wire conductor via welding, where the conductor length from the contact portion to the wire is equal to the plate thickness, allowing for reduced heat generation and efficient heat radiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the plate thickness of the female terminal fitting is increased to reduce conductor resistance, then heat generation is suppressed, but processing cost, material cost and weight increase
Solution Approach 1:
The patent divides the terminal fitting into multiple functional parts: a base plate for mechanical support, a contact piece for electrical contact, and a barrel for wire connection. This segmentation allows each part to be optimized independently, enabling the use of thinner base plates while maintaining low conductor resistance through the optimized contact piece design.
Solution Approach 2:
The patent applies different properties to different parts of the terminal fitting. The contact piece is made with high electrical conductivity and optimized geometry to minimize resistance at the contact point, while the base plate can be thinner since its primary function is mechanical support. This local optimization allows reduced overall thickness without compromising electrical performance.
2Loss of energy
If the plate thickness of the female terminal fitting is increased to reduce conductor resistance, then heat generation is suppressed, but material cost increases
Solution Approach 1:
By segmenting the terminal fitting into a thin base plate and a separately optimized contact piece, the patent reduces the total amount of conductive material needed. The contact piece is precisely shaped to provide the necessary electrical contact with minimal material, while the base plate serves primarily as a mechanical substrate.
Solution Approach 2:
The patent concentrates high-quality conductive material only where it is most needed - at the contact piece that directly interfaces with the male terminal. The base plate can use thinner or less expensive material since it does not carry the full current load, thereby reducing overall material cost while maintaining low heat generation at the critical contact point.
3Loss of energy
If the plate thickness of the female terminal fitting is increased to reduce conductor resistance, then heat generation is suppressed, but weight increases
Solution Approach 1:
The patent separates the weight-bearing function (base plate) from the current-carrying function (contact piece). This allows the base plate to be minimized in thickness for weight reduction, while the contact piece is optimized for electrical performance with minimal material.
Solution Approach 2:
The patent applies high-density conductive material only locally at the contact piece where electrical performance is critical, rather than throughout the entire terminal fitting. The base plate uses minimal material for structural support, significantly reducing overall weight while maintaining low conductor resistance where it matters most.
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 suppresses heat generation without increasing the plate thickness, reducing processing costs and allowing for effective heat dissipation to the connected wire, while maintaining electrical conductivity.
Implementation Method 1
a contact pressure applying portion (16) configured to apply a contact pressure to the male terminal (60)
Implementation Method 2
A conductor of the wire is mounted by welding on a back surface opposite to a surface where the bottom wall and the male terminal are in contact
Implementation Method 3
heat generated due to a contact resistance generated at the contact portion between the male terminal and the female terminal easily can be radiated to the conductor portion of the wire
Data Source
AI summary
A female terminal 10 to be fit to a male terminal 60 and connected to a wire 40 includes a box-shaped female body portion 12 open in a front-rear direction, the male terminal 60 being inserted into the female body portion, a contact pressure applying portion 16 configured to apply a contact pressure to the male terminal 60 inwardly of the female body portion 12 from a ceiling wall 14 of the female body portion 12, and bottom wall contact portions 26 projecting from a bottom wall 24 of the female body portion 12 and configured to contact the male terminal 60. A conductor portion of the wire 40 is mounted by welding on a back surface 28 opposite to a surface where the bottom wall 24 and the male terminal 60 are in contact.