Flat Terminal With Bent Lug And Over-Bending Protection
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Solution Overview
Problem
Existing electrical plug-and-socket connections for trailers and tow vehicles suffer from poor contact due to bending of flat terminals, leading to unreliable connections.
Innovation Solution
The design incorporates a flat terminal with a metal strip terminal body, a connecting end, and a bent contacting lug forming a resilient contact surface, along with a protection mechanism to prevent over-bending, such as a ribbing or wing structure, to maintain contact integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the contacting lug is made resilient by bending it back to form a gap with the terminal body, then the contact surface reliability is improved, but the contacting lug becomes susceptible to over-bending during plug insertion
Solution Approach 1:
The patent applies preliminary action by pre-forming the contacting lug in a bent-back position during manufacturing, creating a controlled gap that establishes the resilient contact surface before the plug is inserted. This preliminary configuration ensures the contact surface is ready to engage reliably while the protection element is already in place to prevent over-bending during operation.
Solution Approach 2:
The protection element against over-bending is pre-installed on the terminal body before the contacting lug is bent back. This preliminary anti-action measure is positioned in advance to counteract and prevent the harmful over-bending motion that could occur during plug insertion, thereby protecting the resilient contact surface from damage.
2Reliability
If the contacting lug is bent back to form a gap for resilient contact, then electrical contact reliability is improved, but the structural stiffness of the terminal is reduced
Solution Approach 1:
The patent segments the terminal structure into distinct functional zones: the terminal body provides structural support and stiffness, while the separated contacting lug creates a resilient contact surface. The gap between the terminal body and contacting lug allows independent movement of the contacting lug, enabling it to maintain reliable electrical contact through elastic deformation while the terminal body remains structurally stable.
Solution Approach 2:
The patent applies local quality by creating a localized resilient zone at the contacting lug while maintaining the overall structural stiffness of the terminal body. The bent-back contacting lug has different mechanical properties (higher flexibility) compared to the terminal body (higher stiffness), allowing each part to perform its specific function optimally - the terminal body provides structural stability while the contacting lug provides reliable electrical contact through localized elastic deformation.
3Duration of action of stationary object
If a protection element is added to prevent over-bending of the contacting lug, then the durability of the terminal is improved, but the device complexity increases
Solution Approach 1:
The patent merges the protection element with the terminal body structure, making it an integrated component rather than a separate attachment. The protection element is formed as part of the terminal body, combining the functions of structural support and over-bending protection into a single unified component, thereby improving durability without significantly increasing overall device complexity.
Solution Approach 2:
The protection element serves multiple functions: it acts as a mechanical stop to prevent over-bending of the contacting lug, provides structural reinforcement to the terminal body, and guides the insertion of the plug. This multi-functionality allows a single component to address multiple concerns (durability, structural integrity, and assembly guidance) without requiring multiple separate parts, thus limiting the increase in device complexity.
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 solution enhances the stiffness of the terminals, prevents over-bending, and ensures reliable electrical connections by maintaining the contact surface within the elastic range, thereby improving the durability and effectiveness of the plug-and-socket connection.
Implementation Method 1
said contacting lug being bent back such that a gap remains between the terminal body and the contacting lug to form a resilient contact surface
Implementation Method 2
a protection against over-bending protruding into said gap to stop a movement of the contacting lug towards the terminal body in a defined distance from the terminal body
Data Source
AI summary
A flat terminal for a socket of an electrical plug-and-socket connection comprising: a terminal body formed by a metal strip; a connecting end extending from one of the axial ends of the terminal body; a contacting lug extending from the other of the axial ends of the terminal body, said contacting lug being bent back such that a gap remains between the terminal body and the contacting lug to form a resilient contact surface; and a protection against over-bending protruding into said gap to stop a movement of the contacting lug towards the terminal body in a defined distance from the terminal body.