Vehicle Power Connector Contact Spring for High-Current Compactness
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Solution Overview
Problem
Conventional high-power connectors for vehicles face issues with increased size due to higher current-carrying capacity, leading to inefficiencies and safety concerns as they become larger, making them more hazardous for operators due to the risk of electric shock.
Innovation Solution
An electrical connection device featuring a blade terminal and tab terminal with a contact spring mechanism that maintains a stable connection even under vibration, reducing the size increase associated with higher current-carrying capacity and enhancing safety by using a blade-type terminal and tab terminal configuration with a U-shaped cross-section and elastic contact springs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the connector terminal uses a conventional annular shape to transmit high voltage and high current, then the current-carrying capacity increases, but the structural radius size increases leading to larger connector size
Solution Approach 1:
The annular contact spring is divided into multiple contact portions (first contact portion, second contact portion, third contact portion) arranged radially. This segmentation allows the current to be distributed across multiple smaller contact points rather than requiring a single large annular structure, thereby maintaining high current-carrying capacity while reducing the overall connector size.
Solution Approach 2:
The contact spring utilizes a three-dimensional spring structure with radial and axial dimensions. The contact portions are positioned at different radial distances from the center, creating a multi-level contact arrangement. This dimensional approach allows efficient current transmission through spatial distribution rather than increasing the planar radius.
2Power
If the size of the high-power connector increases to accommodate higher current capacity, then the current-carrying capacity improves, but the finger safety structure for worker safety deteriorates
Solution Approach 1:
By segmenting the contact spring into multiple smaller contact portions rather than a single large annular contact, the connector achieves the required current capacity through distributed contacts. This segmentation inherently reduces the exposed surface area and minimizes the risk of finger contact with large conductive surfaces, thereby improving operator safety.
3Power
If the connector terminal size increases to transmit higher power, then the power transmission capability improves, but the complexity of the connector structure increases
Solution Approach 1:
The contact spring integrates multiple functions into a single component: it provides mechanical connection, ensures electrical contact, and offers elastic compliance. The multiple contact portions are formed as one integral spring structure, combining what would otherwise require separate elements into a unified component, thereby reducing overall structural complexity while maintaining high power transmission capability.
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 solution provides a stable electrical connection and reduces the size increase related to higher current-carrying capacity, while enhancing safety by maintaining a secure connection and preventing overcurrent, thus addressing the inefficiencies and safety hazards of conventional high-power connectors.
Implementation Method 1
a contact spring assembled in a state of being inserted into an inner side of the first connection portion and configured to connect the terminal body and the tab terminal to each other by being brought into contact with the tab terminal
Data Source
AI summary
An embodiment electrical connection device for a vehicle includes a male connector housing having a blade terminal mounting portion, a female connector housing to couple to the male connector housing and having a tab terminal mounting portion, a blade terminal mounted in the blade terminal mounting portion, and a tab terminal mounted in the tab terminal mounting portion to connect to the blade terminal when the male connector housing and the female connector housing are coupled to each other. An embodiment blade terminal includes a terminal body having a first connection portion and a contact spring inserted into an inner side of the first connection portion to connect the terminal body and the tab terminal to each other by being brought into contact with the tab terminal when the tab terminal is inserted into the inner side of the first connection portion.