Folded Contact Arm Connector for Vibration-Resistant Terminals
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Solution Overview
Problem
Conventional electrical connector systems in motor vehicles face challenges such as space constraints, harsh operating conditions, vibration, and longevity issues, leading to installation difficulties and increased warranty costs due to connector failures.
Innovation Solution
The electrical connector system features a male terminal assembly with a folded or pleated contact arm and an integrally formed internal spring member, eliminating separate spring components, and a female terminal assembly designed to meet industry standards, ensuring secure connections and reduced failure rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrical connector systems are used in motor vehicles, then installation is straightforward, but they suffer from connector failures due to vibration, harsh operating conditions, and space constraints
Solution Approach 1:
The contact arm is divided into multiple folded segments that create multiple contact points with the spring member. This segmentation distributes the mechanical stress and electrical contact load across multiple interfaces, improving reliability under vibration and harsh conditions.
Solution Approach 2:
The contact arm transitions from a linear structure to a folded three-dimensional configuration. This dimensional change increases the thickness and structural rigidity of the contact arm at critical portions, enhancing its ability to withstand vibration and harsh operating conditions while maintaining reliable electrical contact.
2Duration of action of stationary object
If the contact arm is made thicker to increase durability, then longevity improves, but the device complexity increases
Solution Approach 1:
The contact arm employs a folded configuration that provides dynamic flexibility while maintaining structural integrity. The folds allow the contact arm to flex and absorb mechanical stresses from vibration and thermal expansion/contraction, extending connector longevity without requiring excessive material thickness or complex external support structures.
3Ease of manufacture
If separate spring components are used, then the spring assembly can be independently optimized, but the manufacturing complexity and assembly steps increase
Solution Approach 1:
The spring member and contact arm are integrated into a single assembled unit where the folded contact arm interfaces with the spring member at multiple points. This merging reduces the number of separate components and assembly steps while allowing each component to be independently optimized during their respective manufacturing processes, improving ease of manufacture without sacrificing design flexibility.
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 enhances the durability and reliability of electrical connections, reducing installation forces and improving longevity, thereby decreasing warranty costs and enhancing the performance of electrical systems in motor vehicles.
Implementation Method 1
The male terminal has at least one contact arm with a folded or pleated portion that provides additional contact points with the spring member and increases the thickness of said contact arm at that portion
Data Source
AI summary
An electrical connector system having a male connector assembly and a female connector assembly. The male connector assembly includes a male housing and a male terminal assembly that includes a male terminal body and at least one contact arm with a folded or pleated portion that is formed from overlapping contact arm layers which increases the thickness of the contact arm at that portion and provides additional contact points with a spring member. The male terminal assembly also includes a spring assembly with both the spring member and a spring holder that are receivable in the male terminal body. The female connector assembly has a female housing and a female terminal assembly. The female terminal assembly comprises a female terminal connection member and a female terminal body. The female housing is designed to receive the female terminal assembly, facilitate the coupling of the male terminal assembly with the female terminal assembly, minimize the chance that a foreign object accidentally makes contact with the female terminal assembly, and help ensure that the connector system meets industry standards, such as USCAR specifications.