Perpendicular Support Blade Electrical Terminal Design
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Solution Overview
Problem
Existing electrical connectors face challenges in achieving high contact forces with smaller dimensions due to the limitations of thinner metal sheets, which result in reduced contact forces and increased vulnerability to environmental factors like vibrations and contamination.
Innovation Solution
The design incorporates a contact blade with a support blade, where the first and second sheet planes are oriented perpendicularly, allowing the support blade to engage with the contact blade to increase contact force without thickness limitations, and a spring portion for resilient bending, ensuring high contact forces without material thickness dependency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If thinner metal sheets are used to provide smaller terminals, then the dimensions of the terminal are reduced, but the contact force is reduced
Solution Approach 1:
The patent introduces a support blade extending in a direction substantially perpendicular to the contact blade, adding a dimensional element that provides structural support without increasing the terminal's external dimensions. This perpendicular support structure enables thinner metal sheets to maintain adequate contact force capability.
2Force
If stacked contact blades are used to increase contact force, then the contact force is improved, but the terminal cannot be provided at very small dimensions
Solution Approach 1:
Instead of stacking contact blades in the same plane (increasing thickness), the patent extends the support blade in a perpendicular direction, achieving force enhancement through spatial orientation rather than layered stacking, thereby maintaining compact dimensions.
Solution Approach 2:
The terminal is segmented into distinct functional elements: a contact blade for electrical contact and a support blade for structural reinforcement. This segmentation allows each element to perform its specific function efficiently without requiring increased overall size.
3Force
If L-shaped contact blades are used to increase contact force, then the contact force is improved, but the terminal body becomes open to environmental contamination
Solution Approach 1:
The support blade is merged with the terminal body structure, forming an integrated enclosure that protects the contact blade from environmental factors while maintaining the force-enhancing geometry within the closed terminal body.
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 enables the creation of small electrical terminals with high contact forces, reduced strain, and improved durability, maintaining a large contact surface and preventing environmental exposure of the contact blades, thus ensuring secure and reliable electrical connections.
Implementation Method 1
a spring portion (312), arranged between the contact portion (314) and the terminal body (330)
Data Source
Figure 1A~2B
Figure 3A~3B
Figure 4
AI summary
The present invention relates to an electrical terminal 2, 3 for a female connector, wherein the terminal 2, 3 comprises: at least one contact blade 210, 310, having a first sheet plane 318, wherein the contact blade 210, 310 is adapted to contact an electrical pin 250 with a contact force, when the terminal 2, 3 is mated with the electrical pin 250, and at least one separate support blade 220, 320, having a second sheet plane 328, wherein the support blade 220, 320 engages with a corresponding contact blade 210, 310 to increase the contact force, and wherein the first and second sheet planes 318, 328 are orientated substantially perpendicular to each other.