Male Terminal Assembly With Compression Limit for Contact Arm Protection

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Solution Overview

Problem

Conventional electrical connector systems face challenges in motor vehicles due to space constraints, harsh operating conditions, and high failure rates, leading to significant repair and warranty costs, particularly due to incorrect installation and dislodged connectors.

Innovation Solution

The electrical connector system features a male connector assembly with a spring member and a bent contact arm configuration, along with a compression limiting mechanism to prevent excessive deformation, and a female connector assembly with a side wall arrangement to minimize foreign object contact, ensuring reliable coupling and preventing system failure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the contact arm is made more flexible to improve connection reliability, then the ease of coupling is improved, but the risk of excessive deformation and damage increases

Engineering Contradiction:

Improveease of couplingVSAvoidcontact arm durability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent incorporates a compression limiting means that is pre-configured to prevent excessive deformation of the contact arm before it can occur during operation. This preliminary protective structure ensures that while the contact arm remains flexible enough for easy coupling, it cannot be deformed beyond safe limits, thus resolving the contradiction between flexibility and durability

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The compression limiting means acts as a protective cushion that limits the maximum compression force that can be applied to the contact arm. This beforehand cushioning prevents harmful excessive forces while allowing normal operational flexibility, thereby maintaining both ease of coupling and contact arm durability

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Volume of moving object

If the connector assembly is made more compact to meet space constraints, then the volume is reduced, but the protection against foreign object contact is compromised

Engineering Contradiction:

Improveconnector sizeVSAvoidforeign object contact risk

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent employs a nested structure where the contact arm and spring member are housed within a compact enclosure. The compression limiting means is integrated into this nested arrangement, providing foreign object protection without significantly increasing the overall connector volume, thus resolving the contradiction between compactness and protection

Inventive Principle:

Principle #7Nested doll (Nesting)

3Reliability

If the spring member is made stronger to prevent dislodgement, then the reliability is improved, but the force required for coupling increases

Engineering Contradiction:

Improveconnector retentionVSAvoidcoupling force

Core Design Contradiction:

ReliabilityVSForce

Solution Approach 1:

The patent modifies the spring member parameters by incorporating a compression limiting means that changes the force-displacement characteristics of the spring system. This allows the spring member to provide strong retention forces for reliability while limiting the maximum force required during coupling, resolving the contradiction between retention strength and coupling force

Inventive Principle:

Principle #35Parameter changes

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 reliability and durability of electrical connectors by preventing damage from excessive force and foreign object contact, reducing failure rates and associated costs, while meeting industry standards for performance and safety.

Implementation Method 1

a spring member with at least one contact arm

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS20250023272A1Electrical connector system with a male terminal assembly having a compression limiting means

Publication Date: 2025.01.16 EATON INTELLIGENT POWER LTD

AI summary

The present disclosure relates to an electrical connector system having a male connector assembly and a female connector assembly. The male connector assembly includes a male housing assembly and a male terminal assembly having a male terminal, a spring member with at least one contact arm with a significantly bent configuration and an openable jacket that encloses a substantial extent of the male terminal and the spring member. The male terminal assembly also includes a compression limiting means that prevents an external force from overly deforming the contact arm inward. Preventing excessive depression of the contact arm is desirable because it can damage the contact arm and/or the spring member thereby introducing a failure mode to the male connector assembly that can cause the overall connector system to become inoperable and unusable. The female connector assembly includes a female housing assembly and a female terminal assembly. The female housing assembly is designed to receive the female terminal assembly as well as an extent of the male terminal assembly in a connected state during operation of the electrical connector system.