Power Connector Terminal Layout for Stable Plugging Force
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Solution Overview
Problem
Existing power connectors experience a high initial plugging force and reduced plugging force over time due to the use of materials with good elasticity, which affects the mating effect and limits the overall current carrying capacity.
Innovation Solution
A power connector design featuring a first elastic arm with a folded structure and multiple elastic deformation points, allowing for stable plugging and unplugging, while using materials with high conductivity and weak elasticity for the second power terminal to maintain electrical reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If materials with good elasticity are used for both inner layer terminal and outer layer terminal, then plugging and unplugging becomes soft, but electrical conductivity decreases
Solution Approach 1:
The patent applies different material properties to different parts: the inner layer terminal uses materials with good elasticity for soft plugging/unplugging, while the outer layer terminal uses materials with high conductivity for reliable electrical connection. This local differentiation resolves the contradiction between operational ease and electrical reliability.
Solution Approach 2:
The terminal structure is segmented into inner layer terminal and outer layer terminal, each with distinct material characteristics. The inner layer handles mechanical insertion/extraction while the outer layer handles electrical conduction, separating the conflicting requirements into independent functional zones.
2Force
If materials with good elasticity are used for power terminal, then plugging force is initially sufficient, but plugging force decreases after repeated use
Solution Approach 1:
The patent changes the material parameter selection for different terminal layers. The outer layer terminal uses materials optimized for maintaining force over time rather than initial elasticity, ensuring stable plugging force durability while the inner layer provides initial softness.
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 design ensures stable plugging and unplugging forces and improves the overall current carrying capacity by using materials with high conductivity for the second power terminal without compromising the elastic contact reliability.
Implementation Method 1
the first elastic arm adopts a folded structure to form multiple elastic deformation points to disperse the plugging and unplugging force
Data Source
AI summary
A power connector includes an insulating body and a first terminal module. The insulating body has a mating slot configured to receive a mating module. The first terminal module includes a first power terminal and a second power terminal. The first power terminal includes a first main body and a first elastic arm bent back from one end of the first main body. The second power terminal includes a second main body and a first extension arm extending from one end of the second main body. The first elastic arm extends into the mating slot. The first elastic arm is configured to be in direct contact with the mating module. The first extension arm is configured to be electrically connected to the mating module indirectly through the first elastic arm.