Power Connector Elastic Arm Design for Gradual Plugging Feel
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Solution Overview
Problem
Existing electrical connectors lack an optimized design for providing a gradual plugging feel, which affects the insertion experience and contact reliability.
Innovation Solution
The electrical connector features an insulating body with a mating slot and power terminal modules, including elastic arms with raised portions that initially create a gap, allowing for a weak plugging feel during initial insertion, and then deform to provide a strong feel and series connection upon full insertion, facilitating reliable current transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the elastic arm is designed to provide strong contact force, then the plugging feel is strong, but the insertion experience is poor due to excessive resistance from the beginning
Solution Approach 1:
The elastic arm is designed with a dynamic contact force mechanism that changes during insertion. Initially, the elastic arm maintains a larger gap from the power terminal, providing smaller contact force for smooth insertion. Upon full insertion, the elastic arm deforms to reduce the gap and increase contact force, ensuring strong plugging feel and reliable electrical connection.
Solution Approach 2:
The elastic arm is pre-positioned at a specific distance from the power terminal before insertion occurs. This preliminary positioning ensures that during the insertion process, the elastic arm does not immediately contact the power terminal with full force, thereby providing a gradual plugging feel that improves insertion experience.
2Force
If the elastic arm is positioned close to the power terminal, then the plugging feel is strong, but the contact reliability is compromised due to premature contact
Solution Approach 1:
The elastic arm transitions from a non-contact state during insertion to a contact state upon full insertion. The gap between the elastic arm and power terminal dynamically changes: larger during insertion to ensure smooth mating, and smaller after insertion to ensure reliable electrical connection and strong plugging feel.
Solution Approach 2:
The gap distance between the elastic arm and power terminal is used as a controllable parameter that changes with insertion depth. The design specifies a particular gap range that ensures both smooth insertion and reliable contact, with the gap automatically adjusting as the mating module is inserted into the connector.
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 plugging feel by providing a gradual resistance and ensures reliable contact and series connection of power terminals, improving the insertion experience and current transmission capabilities.
Implementation Method 1
the second elastic arm is deformed toward the first power terminal by being abutted by the mating module
Data Source
AI summary
An electrical connector includes an insulating body and a first power terminal module. The insulating body includes a first mating slot for receiving a mating module. The first power terminal module includes a first power terminal and a second power terminal. The first power terminal includes a first elastic arm. The second power terminal includes a second elastic arm. The second elastic arm is provided with a first raised portion. When the mating module is inserted into the first mating slot and inserted in place, the first raised portion is deformed to be in contact with the first power terminal.