Nested Connector Terminals for Miniaturized Power Applications
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Solution Overview
Problem
Existing power connectors are too large due to the inclusion of insulation partition members and elastic clips, which cannot meet the size requirements of miniaturized applications.
Innovation Solution
A connector design featuring conductive terminals with U-shaped fixing portions and elastic contact arms, along with pressing members with U-shaped holding portions and elastic support arms, where the pressing members are fitted within the conductive terminals, reducing external size and enhancing contact force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation partition member and elastic clip are used to surround conductive terminals, then reliability of electrical connection is improved, but overall size of connector increases
Solution Approach 1:
The pressing member is nested within the conductive terminal structure, with the U-shaped holding portion fitting inside the U-shaped fixing portion. This nesting arrangement eliminates the need for separate external insulation partition members and elastic clips, significantly reducing the connector's overall size while maintaining the necessary electrical connection reliability through the integrated elastic support arm that abuts against the elastic contact arm.
Solution Approach 2:
The pressing member integrates multiple functions into a single component: the U-shaped holding portion provides structural support and positioning, while the elastic support arm provides the necessary elastic force for reliable electrical contact. This merging of functions eliminates the need for separate insulation partition members and elastic clips, reducing component count and overall connector size while maintaining connection reliability.
2Volume of moving object
If pressing member is fitted within conductive terminal, then connector size is reduced, but contact force may be insufficient
Solution Approach 1:
The elastic support arm is designed with dynamic characteristics to provide resilient contact force. The arm can deflect and recover, maintaining continuous pressure on the elastic contact arm despite variations in assembly tolerances or thermal expansion. This dynamic elastic force ensures reliable electrical contact while allowing the pressing member to remain compact within the conductive terminal structure.
Solution Approach 2:
The elastic support arm's material properties and geometric parameters are optimized to provide sufficient contact force within a compact form factor. By adjusting the arm's length, thickness, and material elastic modulus, the design achieves the necessary contact force while maintaining the reduced connector size enabled by the nested configuration.
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 design reduces the overall size of the connector while maintaining effective electrical contact and preventing conductive terminal yield, meeting the size requirements of miniaturized applications.
Implementation Method 1
each including a substantially U-shaped fixing portion and an elastic contact arm extending from the U-shaped fixing portion... at least a portion of the elastic support arm abutted against the elastic contact arm
Data Source
AI summary
A connector for electrically connecting to a conductor comprises a pair of conductive terminals, each including a U-shaped fixing portion and an elastic contact arm extending from the U-shaped fixing portion. The connector further includes a pair of pressing members, each having a U-shaped holding portion and an elastic support arm extending from the U-shaped holding portion. Each of the pressing members is fit within the U-shaped fixing portion of the respective conductive terminal by the U-shaped holding portion, and at least a portion of the elastic support arm is abutted against the elastic contact arm.