Overlapping Power Terminal Stacking for High Current Electrical Connectors
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Solution Overview
Problem
Existing electrical connectors are unable to efficiently transmit high currents due to poor contact between power terminals, limiting their effectiveness in applications requiring high current transmission.
Innovation Solution
The electrical connector design includes a power terminal set with overlapping first and second power terminals and an elastic terminal, where the second power terminal is closer to the slot wall, and the elastic terminal is disposed between them, allowing for increased current transmission and improved contact through deformation tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If power terminals are respectively provided on opposite sides of the receiving slot, then the electrical connector can transmit power, but the contact between power terminals is poor and high-current transmission is limited
Solution Approach 1:
The patent transitions from a single power terminal configuration to an overlapping stacked configuration of first and second power terminals. This dimensional change from single-layer to multi-layer arrangement increases the contact area and improves current transmission capacity while maintaining good contact quality between terminals and mating connector.
Solution Approach 2:
The patent combines multiple power terminals (first power terminal and second power terminal) into an integrated power terminal set. By merging these terminals in an overlapping stacked arrangement within the receiving slot, the system achieves both improved contact quality and enhanced current transmission capacity through the combined effect of multiple terminal contacts.
2Reliability
If rigid power terminals are used, then the structure is simple, but the deformation tolerance is insufficient to ensure good contact with mating connector
Solution Approach 1:
The patent introduces an elastic terminal with elastic contacting parts that can dynamically deform to accommodate manufacturing tolerances and assembly variations. This dynamic capability allows the terminal to maintain reliable contact with the mating connector while the overall structure remains relatively simple through the use of elastic materials and straightforward geometric forms.
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 design enhances the ability to transmit high currents while ensuring reliable contact with mating connectors, addressing the limitations of prior art by allowing for greater deformation tolerance and improved contact performance.
Implementation Method 1
the elastic terminal disposed in the accommodating part could have a greater deformation tolerance to ensure that the elastic contacting part has good contact with the mating electrical connector
Data Source
AI summary
The present disclosure provides an electrical connector comprising an insulating body and at least one power terminal module. The insulating body comprises a receiving slot. The power terminal module is disposed in the receiving slot. Each power terminal module comprises a power terminal set and an elastic terminal. The power terminal set is disposed in the receiving slot. The power terminal set comprises a first power terminal, a second power terminal and an accommodating part which are overlappingly stacked. The second power terminal is closer than the first power terminal to the slot wall. The elastic terminal is disposed in the power terminal set, comprising a first end part, a second end part, and a plurality of elastic contacting parts. The plurality of elastic contacting parts is disposed between the first end part and the second end part. The first end part is disposed in the accommodating part.