Internal-Spring Power Connector for Heat- and Vibration-Resistant Retention
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Solution Overview
Problem
Conventional electrical connector assemblies in motor vehicles fail due to premature failure of peripheral spring-actuated elements under harsh automotive conditions, leading to significant repair and warranty costs, and there is a need for a more reliable, vibration-resistant, temperature-resistant, and robust connector system with high ampacity.
Innovation Solution
A connector system featuring a male terminal assembly with an internal spring member and a female terminal assembly that ensures a strong connection under elevated temperatures and high current loads, utilizing a male terminal body with contact arms and a spring member that resists inward deflection, providing a positive connection and retention force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If peripheral spring-actuated elements are used to retain the connector, then engagement indication is improved, but reliability deteriorates due to premature failure under heat and vibration
Solution Approach 1:
The spring element is extracted from the peripheral location and relocated to the interior of the male terminal assembly, where it is protected from environmental factors while still providing retention function
Solution Approach 2:
The spring element is nested within the male terminal assembly, specifically positioned within the terminal body, which protects it from external heat and vibration while maintaining its retention function
2Ease of manufacture
If spring elements are placed on the exterior surface for obvious engagement, then ease of assembly is improved, but temperature resistance deteriorates due to thermal expansion and material degradation
Solution Approach 1:
The spring element is extracted from the exterior surface location and repositioned to the interior of the male terminal assembly, removing it from the thermal environment while preserving its mechanical function
Solution Approach 2:
The spring element is moved from a two-dimensional exterior surface position to a three-dimensional interior position within the terminal body, placing it in a protected thermal zone
3Strength
If peripheral spring tabs are used for connector retention, then mechanical engagement is improved, but vibration resistance deteriorates due to reduced retention force under thermal cycling
Solution Approach 1:
The spring element is nested within the male terminal assembly, protected from environmental factors that cause retention force degradation, while maintaining mechanical engagement strength
Solution Approach 2:
The spring element acts as an intermediary mechanism between the male and female terminal assemblies, providing consistent retention force through its biased position within the terminal body
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 maintains robust mechanical and electrical connection under thermal cycling and high current loads, enhancing reliability and reducing failure rates in harsh environments.
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
At 100° C., the thermal expansion of the spring steel will reduce the retention force of a peripheral spring-actuated connector
Data Source
AI summary
A connector system for use in a power distribution system includes a male terminal assembly, a female terminal assembly and an internal spring. The male terminal assembly includes a male terminal body formed with a spring receiver, a base wall, and a plurality of contact arms extending forward from the base wall and arranged along a curvilinear contact arm path. The contact arms are spatially arranged such that a contact arm opening resides between a pair of contact arms in the plurality of contact arms and no intervening structure of the male terminal body resides between a pair of contact arms in the plurality of contact arms. The internal spring is dimensioned to reside within the spring receiver, and includes a plurality of spring arms arranged along a curvilinear spring arm path. The female connector assembly has a female terminal with a female receptacle. An insertion force of less than 45 Newtons is applied on the male terminal assembly to position an extent of it within the female receptacle to arrive at a fully connected state where the connector system enjoys high ampacity to transfer over 500 amps between the male terminal assembly and the female terminal with less than a 55° C. rise over the ambient temperature in which the connector system is operating.