Power Terminal Connector Vibration Resistance
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Solution Overview
Problem
Existing power terminal connectors in automotive applications face issues with vibration-induced fretting and corrosion due to limited surface area and high electrical resistance in the interface between the spring contact and terminal body.
Innovation Solution
A power terminal connector design featuring a terminal body with notches and posts that securely engage a contact spring with multiple spring beams and tabs, providing a resilient and low-resistance power path through an interference fit, which reduces fretting and enhances contact points for improved electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spring contact is used to create a power path between the terminal body and power terminal, then the connection can accommodate vibration, but the limited surface area leads to high electrical resistance
Solution Approach 1:
The contact spring is divided into multiple spring beams (typically three) that each independently engage with the terminal body. This segmentation increases the total contact surface area and distributes the electrical current across multiple paths, thereby reducing overall electrical resistance while maintaining vibration resistance through the combined effect of multiple contacts.
Solution Approach 2:
The contact spring utilizes a three-dimensional box-shaped structure with spring beams extending in multiple directions rather than a simple planar contact. This dimensional approach allows engagement points to be distributed throughout the depth and width of the terminal body receptacle, increasing the effective contact surface area and reducing electrical resistance.
2Device complexity
If a simple spring contact design is used, then the device complexity is low, but vibration causes fretting and corrosion at the interface
Solution Approach 1:
The contact spring is segmented into multiple spring beams that are independently resilient, allowing each beam to accommodate vibration movements separately. This segmentation reduces fretting at each individual contact interface while maintaining overall structural simplicity. The multiple engagement points distribute mechanical stress, preventing concentrated wear and corrosion.
Solution Approach 2:
The contact spring's physical parameters are optimized by adjusting the thickness, length, and material properties of each spring beam to provide appropriate resilience. This allows the contact to maintain firm electrical connection while accommodating vibration, reducing fretting and corrosion without requiring complex additional components.
3Ease of manufacture
If the contact spring has limited engagement points with the terminal body, then the manufacturing is simple, but the electrical resistance across the interface is high
Solution Approach 1:
The contact spring is segmented into multiple spring beams that naturally create multiple engagement points with the terminal body during assembly. This segmentation achieves low electrical resistance through increased contact surface area without complicating manufacturing, as the segmented structure is formed as a single integrated component that self-aligns during assembly.
Solution Approach 2:
The spring beams are designed to automatically engage with corresponding features in the terminal body receptacle through their own resilient action. This self-service mechanism ensures proper alignment and contact without requiring complex assembly tools or procedures, maintaining ease of manufacture while achieving multiple low-resistance contact points.
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 effectively withstands vibration, reduces electrical resistance, and increases the contact points between the terminal body and power terminal, allowing for higher current flow and minimizing corrosion, thus enhancing the reliability and efficiency of the power connection.
Implementation Method 1
The spring beams resiliently engage the power terminal
Implementation Method 2
The tabs are received in corresponding notches and the gaps receive corresponding posts to secure the contact spring in the terminal box
Data Source
AI summary
A power terminal connector includes a terminal having a terminal body defining a receptacle. The terminal body has a front end open to the receptacle that receives a power terminal. The terminal body has a series of notches separated by posts at the front end. A contact spring is received in the receptacle and has a first band and a second band with spring beams extending between the first and second bands. The spring beams resiliently engage the power terminal. The bands engage the terminal body to create a power path between the terminal body and the power terminal. The first band has a series of tabs extending therefrom separated by gaps. The tabs are received in corresponding notches and the gaps receive corresponding posts to secure the contact spring in the terminal box.