Internal Spring Electrical Connector for Heat and Vibration Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electrical connector systems for motor vehicles face challenges such as premature failure due to harsh environmental conditions, including high temperatures and vibrations, which affect the retention force of spring-actuated connectors, leading to mechanical and electrical connectivity issues.
Innovation Solution
A spring-actuated electrical connector system with an internal spring member nested within the male terminal body, featuring a tubular copper female terminal and contact arms that maintain a strong connection even at elevated temperatures, providing a robust and reliable mechanical and electrical link.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the spring element is located on the periphery of the connector to make engagement obvious, then ease of operation is improved, but reliability deteriorates due to premature failure from heat and vibration
Solution Approach 1:
The spring element is nested inside the male terminal body rather than being positioned on the periphery. This internal placement protects the spring from direct exposure to heat and vibration while maintaining its retention function, resolving the contradiction between visibility and reliability.
Solution Approach 2:
The patent introduces a visible indicator mechanism that is separate from the spring element itself. This indicator serves as an intermediary that provides visual feedback about engagement status without requiring the spring to be exposed, thus maintaining both reliability and ease of operation.
2Ease of manufacture
If conventional eyelet and threaded fastener connectors are used, then manufacturing simplicity is maintained, but reliability deteriorates due to incorrect installation and dislodgement
Solution Approach 1:
The spring-actuated connector design provides self-aligning and self-latching features that guide proper installation and maintain secure connection without requiring complex assembly procedures or tools, thus improving reliability while keeping manufacturing relatively simple.
Solution Approach 2:
The spring element provides dynamic retention force that automatically adjusts to maintain proper connection pressure, compensating for thermal expansion, vibration, and installation variations, thereby enhancing connection stability compared to static fastener designs.
3Reliability
If spring-actuated connectors are used to improve retention, then reliability improves, but device complexity increases due to additional spring components
Solution Approach 1:
The spring element is integrated into the male terminal body as a unified component rather than being a separate external part. This merging reduces the number of discrete components and simplifies assembly while maintaining the retention benefits of spring-actuated design.
Solution Approach 2:
The male terminal body serves multiple functions: it provides structural support, electrical conduction, and houses the spring element for retention. This multi-functionality reduces overall connector complexity by eliminating the need for separate components for each function.
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 system ensures a consistent and robust connection under varying temperature conditions, enhancing the reliability and longevity of electrical connections in high-power, high-voltage applications while resisting vibrations and thermal cycling.
Implementation Method 1
A spring member is nested inside the male terminal body. The spring member resists inward deflection and applies outwardly directed force on the contact arms
Implementation Method 2
A female terminal, such as a tubular copper terminal, is configured to receive an extent of the male terminal assembly
Data Source
AI summary
An electrical connector assembly for electrically and mechanically connecting a component to a power source is disclosed. The connector assembly includes a male terminal with side walls defining a receiver. The side wall includes a contact arm that extends across an aperture in the side wall. The assembly also includes an internal spring member dimensioned to reside within the receiver of the male terminal. The spring member has at least one spring arm that extends from a base portion. The assembly further includes a female terminal with a receptacle dimensioned to receive both the male terminal and the spring member residing within the receiver of the male connector to define a connected position. In the connected position, the spring arm exerts an outwardly directed biasing force on the contact arm of the male terminal to outwardly displace it into engagement with an inner surface of the receptacle to ensure connectivity.