Power Connector Elastic Arm Layout for Higher Current Capacity
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Solution Overview
Problem
The current-carrying capability of existing power connectors is limited due to underutilized spaces between elastic arms, which restricts the power transmission capacity and generates excessive heat during high-current transmission.
Innovation Solution
The power connector design includes a third power terminal with supplementary elastic arms arranged side by side with existing elastic arms, increasing the contact area and utilizing spacing slots, along with additional mounting legs to enhance current transmission capacity and reduce heat generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If additional supplementary elastic arms are added to increase current-carrying area, then the current transmission capability is improved, but the device complexity increases
Solution Approach 1:
The power terminal is segmented into multiple independent elastic arms (first elastic arm, second elastic arm, first supplementary elastic arm, second supplementary elastic arm) that can be separately designed and manufactured. Each elastic arm functions as an independent current conduction path, allowing the system to achieve high current transmission capability through parallel connections of multiple simpler components rather than one complex component
Solution Approach 2:
The supplementary elastic arms are nested within the spacing slots formed by adjacent elastic arms. The first supplementary elastic arm is disposed in the spacing slot between the first elastic arm and second elastic arm, and the second supplementary elastic arm is disposed in the spacing slot between the second elastic arm and first elastic arm, effectively utilizing the available space without increasing the overall footprint of the connector
2Power
If elastic arms are arranged closer together to increase current-carrying area, then the power transmission capability is improved, but the manufacturing precision requirements increase
Solution Approach 1:
Different regions of the power terminal are assigned different functions: the first elastic arm and second elastic arm provide primary contact and current conduction, while the supplementary elastic arms filling the spacing slots provide additional current conduction paths. Each region is optimized for its specific function, with the supplementary arms specifically designed to utilize the spacing slot geometry
Solution Approach 2:
The elastic arms are designed with elastic properties that allow them to automatically adjust their positions and maintain optimal spacing during assembly and operation. The elastic deformation capability enables the arms to self-align and accommodate manufacturing tolerances without requiring extremely tight precision control
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 enhanced design increases the current-carrying area and reduces heat generation, facilitating higher current transmission with reduced resistance.
Implementation Method 1
The first elastic arm includes a first contact surface; the second elastic arm includes a second contact surface; The first supplementary elastic arm includes a first supplementary contact surface; the second supplementary elastic arm includes a second supplementary contact surface
Data Source
AI summary
A power connector includes an insulating body, a first power terminal, a second power terminal and a third power terminal. The first power terminal includes a first fixing portion and a first elastic arm. The second power terminal includes a second fixing portion and a second elastic arm. The third power terminal includes a third fixing portion sandwiched between the first fixing portion and the second fixing portion, a first supplementary elastic arm extending from the third fixing portion, and a second supplementary elastic arm extending from the third fixing portion. The first supplementary elastic arm is extended to be arranged side by side with the first elastic arm. The second supplementary elastic arm is extended to be arranged side by side with the second elastic arm. As a result, the current-carrying area in contact with a mating power connector is increased, which improves the current transmission capability.