Nested Spring Electrical Connector for High-Temperature Retention
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Solution Overview
Problem
Current spring-actuated electrical connectors in motor vehicles fail due to peripheral spring mechanisms that are prone to thermal degradation and reduced retention force under high temperatures, leading to intermittent connections and increased susceptibility to vibration.
Innovation Solution
A high-power, spring-actuated electrical connector design featuring a metallic tubular male terminal with a nested spring actuator inside the female connector, where the spring actuator's thermal expansion and material memory increase retention force, ensuring a robust and reliable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If a peripheral spring-actuated feature is used to retain the connector, then engagement visibility is improved, but retention force is reduced at high temperatures
Solution Approach 1:
The patent moves the spring-actuated retention feature from the periphery to the interior of the connector, nesting it within the contact element structure. This interior spring mechanism maintains retention force at high temperatures while the outer housing provides the visible engagement indicator, thus resolving the contradiction between visibility and retention force.
2Force
If spring steel is used for the spring-actuated feature, then retention force is improved, but thermal cycling reduces retention force over time
Solution Approach 1:
The patent changes the material parameter from spring steel to beryllium copper alloy for the spring-actuated feature. This material substitution maintains retention force consistency through thermal cycling because beryllium copper has superior thermal stability and resistance to material memory effects, thus resolving the reliability issue while preserving retention force.
3Ease of manufacture
If plastic is used for the spring-actuated feature, then manufacturing cost is reduced, but retention force is significantly reduced at high temperatures
Solution Approach 1:
The patent employs a composite material solution where the contact element is made of beryllium copper alloy (a metal) while the outer housing remains plastic. This allows the critical spring-actuated retention feature to have superior high-temperature performance while the overall connector maintains cost-effective plastic manufacturing, thus resolving the contradiction between manufacturing cost and retention force.
4Ease of operation
If the spring element is placed on the periphery, then engagement indication is improved, but susceptibility to vibration is increased
Solution Approach 1:
The patent nests the spring-actuated retention feature inside the contact element rather than placing it on the periphery. This interior positioning protects the spring mechanism from vibration while the outer housing structure maintains the visible engagement indicator, thus resolving the contradiction between engagement indication and vibration resistance.
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 maintains a consistent retention force and electrical contact at elevated temperatures, enhancing durability and resistance to vibration, thus reducing failure rates and improving connectivity in harsh automotive environments.
Implementation Method 1
the spring actuator's thermal expansion and material memory increase retention force
Implementation Method 2
the spring actuator's thermal expansion and material memory increase retention force
Data Source
AI summary
The present invention provides an electrical connector assembly for use in a high-power application, such as with motor vehicle electronics, that exposes the connector assembly to elevated temperatures and thermal cycling. The connector assembly includes a first electrically conductive connector formed from a first material, an internal spring member formed from a second material residing within the first connector, and a second electrically conductive connector with a receptacle dimensioned to receive both the first connector and the spring member to define a connected position, wherein the connector assembly withstands the elevated temperatures and thermal cycling resulting from the high-power application. To maintain the first and second connectors in the connected position, the spring arm of the spring member exerts an outwardly directed force on the contact beam of the first connector to outwardly displace the contact beam into engagement with an inner surface of the receptacle of the second connector.