Nested Female Terminal Structure for High-Current Power Tool Packs
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Solution Overview
Problem
Existing lithium battery packs in power tools have limited discharge capacity due to small contact areas between male and female terminals, leading to high temperatures and safety risks, and require significant space, which is not suitable for compact designs.
Innovation Solution
A female terminal design with dual resilient openings and clamping arms that increase contact area and current flow capacity by allowing sequential insertion and connection of male terminals, enhancing stability and discharge capacity in a confined space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional single electrical connector structure is used, then device complexity is low, but current flow capacity is limited and contact area is small
Solution Approach 1:
The female terminal is divided into multiple independent electrical connectors (first electrical connector and second electrical connector), each capable of independently contacting male terminals. This segmentation increases the total current flow capacity by providing multiple parallel current paths while maintaining manageable structural complexity through modular design
Solution Approach 2:
The second electrical connector is nested inside the first electrical connector, with both connectors sharing the same insertion direction and axis. This nested configuration increases current flow capacity by adding another contact interface without significantly increasing the overall footprint or structural complexity
2Volume of moving object
If male terminals are placed side by side or front to back, then electrical connection is simple, but space volume is too large
Solution Approach 1:
The nested arrangement of electrical connectors allows the second connector to be positioned inside the first connector along the same insertion axis. This reduces the overall space volume required for the terminal interface while maintaining reliable electrical connections through multiple contact points
Solution Approach 2:
Instead of placing male terminals side by side (horizontal arrangement) or front to back (depth arrangement), the invention uses a nested configuration where connectors are arranged along the insertion depth dimension. This dimensional reorganization reduces the horizontal and vertical footprint while maintaining connection reliability
3Temperature
If small contact area between male and female terminals is used, then device size is compact, but temperature increases and safety risks occur
Solution Approach 1:
The current path is segmented into multiple parallel pathways through the first and second electrical connectors. Each connector provides its own contact area for current flow, effectively distributing the thermal load across multiple contact points. This increases the total effective contact area without proportionally increasing the terminal size
Solution Approach 2:
The nested configuration allows the second electrical connector to be positioned inside the first connector, maximizing the use of available space. This arrangement increases the total contact area for current flow while keeping the overall terminal size compact, as both connectors share the same spatial envelope
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 dual resilient openings and clamping arms enhance current flow capacity and discharge capacity, improving the stability and performance of power tools and battery packs in a compact form factor.
Implementation Method 1
The first electrical connector is provided with a first resilient opening configured for an electrical connection and insertion of the male terminal
Data Source
AI summary
A female terminal, a socket, a battery pack, a power tool and a power tool system are provided to improve a problem of limited discharge capacity between a conventional battery pack and a power tool. The female terminal is used for an electrical connection with a male terminal, and the female terminal includes: a first electrical connector and a second electrical connector. The first electrical connector is provided with a first resilient opening to be electrically connected and inserted into the male terminal. The second electrical connector is arranged inside the first electrical connector, and is provided with a second resilient opening to be electrically connected and inserted into the male terminal. Wherein, during an electrical connection, the male terminal sequentially enters the first resilient opening and the second resilient opening in sequence, and is electrically connected to the first electrical connector and the second electrical connector.