Nested Spring Power Connector for Heat-Stable Retention
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Solution Overview
Problem
Current high-voltage and high-power electrical connectors in motor vehicles are prone to failure due to vibration and thermal stress, as the retention force of peripheral spring-actuated features decreases with temperature changes, leading to intermittent connections and connector loosening.
Innovation Solution
A spring-actuated electrical connector design where a metallic tubular member with a nested spring member applies an outward force to contact beams, increasing retention force with thermal expansion, ensuring stable connections under high-power and high-voltage conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a peripheral spring-actuated feature is used to retain the connector, then engagement is made obvious to the assembler, but the retention force decreases with increased temperature leading to connector failure
Solution Approach 1:
The spring member is nested inside the first connector rather than being placed peripherally on the exterior surface. This internal positioning protects the spring from thermal degradation while maintaining its retention function, resolving the contradiction between ease of operation and reliability.
Solution Approach 2:
The contact beams act as intermediaries between the nested spring member and the second connector. The spring forces the contact beams outward to engage with the second connector, providing both reliable retention and clear engagement indication without exposing the spring to thermal damage.
2Force
If spring steel is used for the spring-actuated feature, then retention force is initially strong, but material memory causes the spring to return to its original shape after thermal cycling, reducing retention force
Solution Approach 1:
By nesting the spring member inside the first connector, it is protected from extreme thermal cycling that would trigger material memory effects. The internal position maintains more stable temperature conditions, preserving the spring's retention force over time.
Solution Approach 2:
The patent changes the physical parameters of the spring system by nesting it internally and using contact beams as force transmission elements. This configuration modifies the thermal and mechanical parameters experienced by the spring, reducing the impact of material memory while maintaining retention force.
3Ease of manufacture
If the spring element is placed on the exterior surface of the connector, then engagement is visible, but the spring is prone to failure from vibration and heat
Solution Approach 1:
The spring member is nested inside the first connector, protecting it from vibration and heat while maintaining assembly visibility through the contact beams that extend outward to engage with the second connector.
Solution Approach 2:
The contact beams serve as intermediaries that transmit force from the protected nested spring to the second connector. This allows the spring to remain shielded from harmful environmental factors while still providing visible and tactile engagement feedback.
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 assembly maintains a consistent retention force and electrical contact even at elevated temperatures, reducing the likelihood of connector failure due to thermal cycling and vibration.
Implementation Method 1
A spring member is nested inside the first connector... the spring member applies an outwardly directed force on the contact beams
Implementation Method 2
At 100° C., the thermal expansion of the spring steel will reduce the retention force of a peripheral spring-actuated connector
Data Source
AI summary
A spring-actuated electrical connector assembly for electrically and mechanically connecting a device to a power source in high-power, high-voltage applications is disclosed. The connector assembly includes a first connector with an internal receiver, a plurality of side walls, and at least one contact beam. The contact beam integrally extends to an outer surface of the side wall and includes a free end that extends inward of the outer surface of the side wall. An internal spring member is dimensioned to reside within the receiver of the first connector. This assembly also includes a second electrically conductive connector with a receptacle dimensioned to receive both the first connector and the spring member to define a connected position during operation of the device. In the connected position, at least one 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 the second connector.