Flat Female Terminal Spring Cage for High-Vibration HV Connections
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Solution Overview
Problem
Conventional flat socket terminals for high-voltage connections struggle to meet vibration requirements, particularly at severity levels 3 and 4, due to relative movements between plugged-together socket and tab terminals, leading to costly and space-intensive solutions.
Innovation Solution
A vibration-resistant electromechanical flat socket terminal design featuring a cuboid tab contact receptacle with a contact spring cage made from steel, which is either a single piece or multiple parts, providing enhanced mechanical and electrical contact through a combination of cover and side contact springs, allowing for independent adjustment of vibration strength and normal force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flat socket terminals are used for high-voltage connections, then the design is simple and cost-effective, but the vibration requirements at severity levels 3 and 4 cannot be met due to relative movements between socket and tab terminals
Solution Approach 1:
The patent applies the dynamics principle by introducing a spring cage with elastic contact springs that can dynamically adapt to vibrations and relative movements. The spring mechanism allows the terminal to maintain reliable electrical contact under vibrational loads while absorbing mechanical stresses, thereby meeting severe vibration requirements without requiring overly complex rigid structures.
Solution Approach 2:
The patent employs composite materials by combining the spring cage made of elastic material (such as phosphor bronze or spring steel) with the socket terminal body made of conductive material (such as copper or aluminum alloy). This composite construction provides both the mechanical flexibility needed for vibration resistance and the electrical conductivity required for high-voltage connections, resolving the contradiction between reliability under vibration and structural simplicity.
2Reliability
If additional measures are taken to produce the retaining forces required for vibration resistance, then vibration requirements can be met, but the solution becomes cost-intensive and requires additional structural space
Solution Approach 1:
The patent merges the functions of the socket terminal body and the retaining spring mechanism into an integrated assembly. The spring cage is designed to be mounted directly on the socket terminal, combining the electrical connection function and the vibration-resistant retaining function into a single compact structure. This eliminates the need for separate additional components, reducing manufacturing costs and simplifying production while maintaining vibration resistance at severity levels 3 and 4.
3Reliability
If copper-based solutions are used for vibration-resistant terminals, then vibration requirements can be met, but the cost increases significantly
Solution Approach 1:
The patent applies local quality by using different materials for different functional requirements: the spring cage is made of elastic material (such as phosphor bronze or spring steel) optimized for mechanical retention and vibration resistance, while the contact elements are made of conductive material (such as copper or aluminum alloy) optimized for electrical conductivity. This localized material selection allows the terminal to meet vibration requirements without requiring expensive copper-based solutions throughout the entire structure, thereby reducing manufacturing costs while maintaining reliability.
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 design effectively meets vibration requirements of severity level 3 and 4, reduces plugging force, and is cost-effective compared to copper-based solutions, while maintaining high voltage and current ratings.
Implementation Method 1
a contact spring cage 20, formed as a single piece or as multiple parts, for mechanically and electrically contacting the tab contact section
Implementation Method 2
providing enhanced mechanical and electrical contact through a combination of cover and side contact springs, allowing for independent adjustment of vibration strength and normal force
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a vibration-resistant electromechanical flat socket terminal (1), in particular a high-voltage flat socket terminal (1), for an electrical connection, in particular a high-voltage connection for a vehicle, in particular a vehicle with an electric traction motor, with an essentially cuboid tab contact receptacle (250) into which an essentially cuboid tab contact section (550) of an electrical mating terminal (5), in particular a high-voltage mating terminal (5), for making electrical contact with the flat socket terminal (1) can be plugged, wherein the tab contact receptacle (250) is formed between a plug contact section (110) of an electromechanical connection piece (10) and a mechanical contact spring cage (20), formed apart therefrom, of the flat socket terminal (1).