Flat Terminal Connector With Oblique Coil Spring
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Solution Overview
Problem
The high manufacturing cost of connectors using obliquely wound coil springs is due to the need for high dimensional accuracy and complex cutting processes, particularly in hollow cylindrical terminals and groove structures.
Innovation Solution
A connector design featuring a flat plate terminal with an obliquely wound coil spring that is sandwiched between the terminal and a mating terminal, utilizing a connector housing with a rotation restricting portion to control the spring's rotation and insertion posture, reducing the likelihood of the spring catching the mating terminal and simplifying the manufacturing process through press-working.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a hollow cylindrical terminal with high dimensional accuracy is used to fit the obliquely wound coil spring, then the spring can be properly positioned and held, but the manufacturing cost increases due to complex cutting processes and high precision requirements
Solution Approach 1:
The patent replaces the expensive hollow cylindrical terminal requiring high precision cutting with a simple flat plate terminal that can be manufactured through cost-effective press-working processes. The flat plate terminal achieves the same functional purpose of holding and positioning the obliquely wound coil spring without requiring complex manufacturing processes or high dimensional accuracy.
2Adaptability or versatility
If the obliquely wound coil spring is allowed to rotate freely, then it can accommodate insertion variations, but the mating terminal may be caught by the spring making insertion difficult
Solution Approach 1:
The patent introduces asymmetric features through the rotation restricting portion that allows the obliquely wound coil spring to rotate only in a specific direction or to a specific position. This asymmetric constraint prevents the spring from rotating to positions where it would catch the mating terminal, while still allowing sufficient rotation to accommodate normal insertion variations. The asymmetric design resolves the contradiction by providing controlled adaptability without excessive rotation.
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 reduces manufacturing costs by eliminating the need for complex cutting and ensuring easy insertion of the mating terminal while maintaining effective electrical connection through the obliquely wound coil spring.
Implementation Method 1
An obliquely wound coil spring formed by spirally winding a conductive wire with respect to a winding axis is disposed such that the winding axis thereof and the terminal are parallel. The coil spring is sandwiched between the terminal and a mating terminal
Data Source
AI summary
A connector (C) includes a flat terminal (20), an obliquely wound coil spring (10) wound around a winding axis (A) that is parallel to the terminal (20) with the coil spring (10) sandwiched between the terminal (20) and a flat mating terminal (71). A connector housing (30) accommodates the terminal (20) and the coil spring (10) and includes an insertion path (37) for the mating terminal (71) to be parallel to the terminal (20). A rotation restricting portion (33) is in the connector housing (30) and restricts the coil spring (10) in a rotation posture to tilt with respect to the winding axis (A) such that a mating terminal side of a half-turn winding plane and a straight line connecting a start point (P1) and an end point (P2) of the half turn is on a back side in an inserting direction of the mating terminal (71).