Metal Case Connector Resists Creep Under High Biasing Force
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Solution Overview
Problem
Existing connectors face reliability issues due to creep phenomenon and resin collapse when exposed to high environmental temperatures and large biasing forces from coil springs, particularly when made of synthetic resin materials.
Innovation Solution
A connector design featuring a metal case with a movable terminal and a coil spring, where the first conductive member is sandwiched between the coil spring and the case's ceiling wall, allowing further compression and distributing the biasing force through a double structure, including thick portions on the housing's upper wall to disperse the force and prevent creep.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the case is made of synthetic resin material, then the connector is reduced in weight and manufacturing cost, but the case may experience creep phenomenon and resin collapse under high contact pressure and high environmental temperature
Solution Approach 1:
The patent employs a composite material structure where the case is made of metal material (such as aluminum alloy or stainless steel) to provide high strength and creep resistance under high temperature and pressure conditions. This metal construction ensures the case can withstand the biasing force of the coil spring and contact pressure without deformation, resolving the reliability issue while accepting increased weight compared to pure resin construction.
2Force
If the coil spring is designed to provide large biasing force, then the contact pressure between terminals is improved, but the case may experience creep phenomenon and structural failure
Solution Approach 1:
The case is constructed from metal material with high mechanical strength to resist the large biasing force generated by the coil spring. The metal material prevents creep phenomenon and structural failure that would occur with resin materials under such high forces, ensuring the case maintains its structural integrity while allowing the coil spring to provide sufficient contact pressure for reliable terminal connection.
Solution Approach 2:
The patent incorporates a curved support surface in the case that supports the coil spring. This curved structure distributes the biasing force more evenly across the case structure, reducing stress concentration and preventing localized deformation or creep, thereby enhancing the case's ability to withstand large coil spring forces.
3Force
If the ceiling wall of the case receives high contact pressure from the coil spring, then the terminal connection is secured, but the case may experience deformation and reduced reliability
Solution Approach 1:
The ceiling wall is made of metal material with high strength-to-weight ratio, enabling it to withstand high contact pressure from the coil spring without deformation. The metal construction provides sufficient structural strength to maintain the case's integrity under the compressive loads generated during terminal connection, preventing the ceiling wall from collapsing or deforming.
Solution Approach 2:
The patent introduces a curved support surface that distributes the contact pressure from the ceiling wall across a larger area and different spatial dimensions. This dimensional distribution of stress reduces the peak pressure on any single point of the ceiling wall, preventing localized deformation while maintaining overall connection strength.
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 connector effectively withstands high environmental temperatures and large biasing forces, maintaining reliability by preventing creep and allowing the use of stronger coil springs, while reducing the connector's weight and thickness.
Implementation Method 1
A coil spring is accommodated inside the case while being compressed in a compression direction toward the ceiling wall of the case
Data Source
AI summary
A connector (1) includes a terminal (10) and a housing (H) for accommodating the terminal. The terminal (10) includes a case (20) having a ceiling wall (21) and accommodated in the housing, a coil spring (30) accommodated inside the case while being compressed in a compression direction toward the ceiling wall of the case, and a first conductive member (40) having a contact portion (43) with a mating terminal and sandwiched between one end (31) of the coil spring and an inner wall of the case, the contact portion being movable in the compression direction to further compress the coil spring. The case (20) is made of a metal material.