Obliquely Wound Coil Spring Terminal Module
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing terminal modules face challenges in miniaturization and cost-effectiveness due to the need for annular spring contacts, which increase contact resistance and are prone to settling, especially when used on smooth surfaces.
Innovation Solution
An obliquely wound coil spring is used with a conductive wire material, where the coil axis is parallel to the body and tilted during mating, and at least one of the sliding surfaces is formed into an uneven surface to increase frictional resistance, reducing contact resistance and allowing for thinner wire usage without compromising reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the spring contact is used in an annular state, then the contact pressure is maintained, but the manufacturing cost increases due to groove formation and miniaturization becomes difficult
Solution Approach 1:
Instead of forming grooves in the busbar surface to hold the annular spring contact, the patent inverts the approach by making the spring contact itself annular and having it slide on the smooth busbar surface. The spring contact maintains contact pressure through its elastic deformation while sliding along the smooth surface, eliminating the need for expensive groove formation operations.
2Ease of manufacture
If the spring contact is used in a straight state, then the manufacturing cost decreases, but the contact pressure is insufficient on smooth surfaces due to sliding
Solution Approach 1:
The patent applies curvature by forming the spring contact in an annular shape rather than using a straight configuration. This annular geometry allows the spring contact to effectively engage with and maintain pressure against the busbar surface through elastic deformation, while still being manufacturable without expensive groove formation operations.
3Reliability
If the conductive wire material is thickened to increase contact pressure, then the contact resistance decreases, but the terminal module size increases and flexibility is reduced
Solution Approach 1:
The patent employs a dynamic spring contact mechanism that can elastically deform and adapt to the busbar surface. This dynamic capability allows a thin-walled spring contact to maintain adequate contact pressure through its elastic recovery, eliminating the need for thick wire material while keeping the terminal module compact and maintaining manufacturing flexibility.
Solution Approach 2:
The patent changes the geometric parameters of the spring contact, specifically forming it in an annular shape with optimized dimensions. This parameter optimization allows the spring contact to achieve sufficient contact pressure with thinner wire material, reducing the terminal module size while maintaining electrical contact reliability.
4Reliability
If the conductive wire material is thickened to increase contact pressure, then the contact resistance decreases, but the flexibility is reduced causing the spring contact to settle easily
Solution Approach 1:
The patent employs a dynamic spring contact mechanism that can elastically deform and adapt to the busbar surface. This dynamic capability allows a thin-walled spring contact to maintain adequate contact pressure through its elastic recovery, eliminating the need for thick wire material while keeping the terminal module compact and maintaining manufacturing flexibility.
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
This configuration enhances contact pressure, reduces contact resistance, and allows for miniaturization while maintaining connection reliability, and eliminates the need for expensive groove formation, enabling larger current applications and easier processing.
Implementation Method 1
at least one of a facing surface on the body of the electrical contact on which the obliquely wound coil spring slides and a contact surface on the butting portion of the mating terminal on which the obliquely wound coil spring slides is formed into an uneven surface for increasing frictional resistance during sliding
Implementation Method 2
The coil spring is oriented such that a coil axis is parallel to the body of the electrical contact, and is configured to be sandwiched between the mating terminal and the electrical contact member to be tilted toward the coil axis when the mating terminal and the electrical contact member approach
Data Source
AI summary
A terminal module includes an electrical contact having a body (30) configured to face a butting portion (82) on a mating terminal, oriented such that a coil axis (P) is parallel to the body (30) of the electrical contact member and configured to be sandwiched between the mating terminal and the electrical contact (20) to be tilted toward the coil axis (P) when the mating terminal and the electrical contact (20) approach. At least one of a facing surface (31) on the body (30) of the electrical contact (20) on which the obliquely wound coil spring (60) slides and a contact surface (81) on the butting portion (82) of the mating terminal on which the obliquely wound coil spring (60) slides is formed into an uneven surface for increasing frictional resistance during sliding.