Flat Electrical Connector for Airbag Systems
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Solution Overview
Problem
Electrical connectors used in space-constrained applications, such as airbag systems in cars, require a compact design while maintaining reliability and functionality, as traditional designs are often bulky due to bending processes during terminal production.
Innovation Solution
A flat female contact terminal with flexible spring arms extending perpendicular to the mating direction, cut from sheet metal, eliminates the need for bending, allowing for a low-profile design with symmetric spring arms that can flex to establish a mechanical and electrical connection, and a connector housing with guide members to ensure proper alignment and force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional bending processes are used to produce female contact terminals, then the terminals can establish reliable electrical connections, but the connector height increases and space is consumed
Solution Approach 1:
Instead of bending the terminal body to create spring arms, the invention inverts the approach by keeping the terminal body flat and extending spring arms perpendicular to the mating direction. This inversion of the traditional bending approach allows the terminal to maintain a low profile while still providing reliable electrical connection through the perpendicular spring arms that engage with male terminals.
Solution Approach 2:
The invention transitions from a traditional design where spring arms extend parallel to the mating direction to a design where spring arms extend perpendicular to the mating direction. This dimensional change allows the terminal to achieve reliable electrical connection in a different spatial orientation, thereby reducing the connector height in the mating direction while maintaining connection reliability.
2Reliability
If traditional bending processes are used to produce female contact terminals, then the terminals can establish reliable electrical connections, but the manufacturing complexity increases
Solution Approach 1:
The invention inverts the traditional manufacturing approach by eliminating the bending step for the terminal body. Instead of bending the terminal to create spring arms, the design uses a flat terminal body with perpendicular spring arms that can be formed through simpler processes such as stamping or extrusion, thereby reducing manufacturing complexity while maintaining connection reliability.
Solution Approach 2:
The invention changes the geometric parameters of the terminal design from a bent configuration to a flat configuration with perpendicular spring arms. This parameter change simplifies the manufacturing process by eliminating complex bending operations while maintaining the functional requirements for reliable electrical connection through the spring arms.
3Reliability
If traditional bending processes are used to produce female contact terminals, then the terminals can establish reliable electrical connections, but the connector profile becomes bulky
Solution Approach 1:
The invention inverts the traditional terminal design by using a flat terminal body instead of a bent one. This inversion allows the spring arms to extend perpendicular to the mating direction, creating a low-profile connector design that is not bulky, while still providing reliable electrical connection through the perpendicular spring arm engagement.
Solution Approach 2:
The invention changes the orientation of spring arms from parallel to perpendicular relative to the mating direction. This dimensional change allows the connector to achieve a sleek, low-profile shape without the bulk associated with traditional bent terminal designs, while maintaining reliable electrical connection through the perpendicular spring arm configuration.
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 solution results in a significantly reduced connector height, simplified manufacturing, and enhanced reliability by preventing unwanted movement of the terminal, ensuring a secure and efficient electrical connection in space-limited environments.
Implementation Method 1
the flexible spring arms may be provided such that they can flexibly bend essentially perpendicular to both, the extension direction of the female contact terminal and the mating direction
Data Source
AI summary
The invention relates to an electrical connector (1), adapted to be mated with a corresponding counter connector (3) in a mating direction (100). The electrical connector (1) comprises at least one female contact terminal (10) extending at least partially perpendicular to the mating direction (100) in an extension direction (200). The female contact terminal (10) comprises a distal portion (12) with two flexible spring arms (14) extending in extension direction (200). An engagement portion (16) is formed between the flexible spring arms (14) and is adapted to engage a corresponding male terminal (50) of the counter connector (3). The electrical connector (1) further comprises a connector housing (30) comprising at least one terminal cavity (32), adapted to house the female contact terminal (10). The terminal cavity (32) is adapted to essentially prevent movement of the female contact terminal (10) parallel to both, the mating direction (100) and the extension direction (200).