Metal Reed Connector Structure for Multi-Direction High-Current Contact
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Solution Overview
Problem
Existing high-voltage connectors face challenges with high cost, low production efficiency, limited current-carrying capacity, and restricted plugging and unplugging directions, requiring multiple female terminals for different directional requirements.
Innovation Solution
A metal reed structure that allows for 90° and 180° pluggable installation of male and female terminals, enabling direct electrical connection without additional adapter mechanisms, and featuring wavy connecting and cantilever reeds for stable contact and improved current-carrying capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional machining methods are used to form male terminals and female terminals, then connection functionality is achieved, but production cost increases, production efficiency decreases, and current-carrying capacity is limited
Solution Approach 1:
The patent changes the material parameter from traditional machined metal to metal reed material with superior electrical conductivity and mechanical properties. The metal reed structure achieves both high current-carrying capacity and ease of manufacture through its inherent material characteristics and simplified forming process, resolving the contradiction between production efficiency and current-carrying capacity
Solution Approach 2:
The terminal structure is segmented into multiple flexible reed elements instead of a single rigid machined piece. This segmentation allows each reed to independently make contact, increasing effective contact area and current-carrying capacity while simplifying the manufacturing process through repetitive forming of identical reed units
2Adaptability or versatility
If traditional rigid terminal structures are used, then structural strength is maintained, but plugging and unplugging directions are limited and multiple female terminals are needed for different directions
Solution Approach 1:
The female terminal is designed with multiple flexible reed elements that can adapt to different plugging directions (90° and 180°). This single universal female terminal structure replaces the need for multiple direction-specific terminals, achieving multi-functionality while reducing device complexity
Solution Approach 2:
The rigid terminal structure is replaced with dynamic flexible reed elements that can bend and adapt to different insertion angles. This dynamic structure allows the terminal to accommodate various plugging directions without requiring multiple fixed-orientation terminals
3Reliability
If rigid connecting structures are used, then structural stability is maintained, but contact stability during vibration decreases
Solution Approach 1:
Rigid connecting structures are replaced with flexible metal reed elements that can elastically deform. These flexible reeds maintain stable contact during vibration through elastic recovery, while the overall structural stability is preserved through proper reed design and support structures
4Productivity
If single-point contact structures are used, then structural simplicity is maintained, but temperature rise increases and current-carrying capacity is limited
Solution Approach 1:
Multiple metal reed elements are combined to work together in parallel, creating multiple contact points that distribute the current load. This merging of multiple contact paths increases overall current-carrying capacity while reducing current density and temperature rise at each individual contact point
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 metal reed structure facilitates assembly, reduces costs, ensures stable contact resistance, and enhances current-carrying capacity by dispersing force and reducing temperature rise, while allowing for versatile directional connections.
Implementation Method 1
the connecting reeds and the cantilever reeds are of wavy structure that can elastically deform, which ensures that the connecting reeds and the cantilever reeds are always kept in contact with the male terminal or the female terminal even if the female terminal or the male terminal moves when vibration occurs during use
Data Source
AI summary
A metal reed structure and an electrical connector. The metal reed structure includes: a first side plate and a second side plate disposed opposite to each other, and a third side plate and a fourth side plate disposed opposite to each other, where the first side plate and the third side plate are located in a same plane, and the second side plate and the fourth side plate are located in a same plane; and at least one pair of first connecting reed and second connecting reed disposed opposite to each other, where two ends of the first connecting reed are connected to the first side plate and the third side plate respectively, and two ends of the second connecting reed are connected to the second side plate and the fourth side plate respectively.