Radial Contact Spring Terminal Fitting for Compact Connectors
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Solution Overview
Problem
Existing terminal fitting connection structures face challenges in reducing the size of connectors while maintaining stable electrical connections, as they often require increased axial length for contact spring flexibility and have limited contact areas, leading to higher conductor resistance.
Innovation Solution
A terminal fitting connection structure with contact spring pieces arranged on an annular portion of the terminal fittings, allowing them to extend radially and reduce axial length, combined with a rotary connector design that includes a locking mechanism to secure the connection, enhancing contact area and reducing conductor resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the contact spring piece extends in the axial direction to ensure sufficient length for flexibility, then the flexibility and stability of the contact spring are improved, but the axial length of the terminal fitting increases, leading to increased connector size
Solution Approach 1:
The contact spring piece is configured to extend in the radial direction from the annular portion rather than axially, changing the dimension of extension from axial to radial. This allows the contact spring to achieve sufficient length for flexibility while keeping the axial length of the terminal fitting compact, directly resolving the technical contradiction between contact spring flexibility and terminal fitting size
2Reliability
If the contact area between contact spring piece and contact surface is increased to reduce conductor resistance, then the electrical connection reliability is improved, but the structural complexity of the terminal fitting increases
Solution Approach 1:
The contact spring piece is divided into multiple contact portions along its extension, each capable of contacting the contact surface. This segmentation increases the total contact area and improves electrical connection reliability while maintaining a relatively simple overall structure through the annular configuration
Solution Approach 2:
The terminal fitting uses an annular (curved) configuration for the contact spring piece instead of a straight linear design. This curved geometry naturally increases the contact area with the contact surface while maintaining structural simplicity, resolving the contradiction between contact area and structural complexity
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 configuration reduces the axial length of terminal fittings, decreases conductor resistance, and enhances the reliability of electrical connections, allowing for a more compact connector design suitable for vehicles with limited installation space.
Implementation Method 1
a contact spring piece 111 provided in a first terminal fitting 110 comes into pressing contact with a contact surface 121 provided in a second terminal fitting 120
Data Source
AI summary
A second terminal fitting which abuts and is connected to a first terminal fitting includes a second annular portion formed at the tip end of a second terminal body which extends on a center axis thereof, a plurality of contact surfaces which protrude from the outer periphery of the second annular portion at the same intervals as those of a plurality of contact protrusions in the first terminal fitting, and a plurality of contact release portions which are positioned between the adjacent contact surfaces.