Ribbed Contact Spring Terminal for Low Insertion Force
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Solution Overview
Problem
Traditional socket terminals have high insertion mating forces, causing ergonomic issues and requiring higher forces for connection and disconnection, which is not desirable, especially under conditions of vibration and strain.
Innovation Solution
The terminal features ribbed contact springs with a reduced contact spring rate and a longer aspect-ratio, allowing for more controlled normal force and increased deflection, thereby reducing the insertion force required and maintaining a stable electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional socket terminals are used, then the connection is stable under vibration and strain, but the insertion mating force is high causing ergonomic problems
Solution Approach 1:
The patent changes the geometric parameters of the contact springs by introducing a longer aspect ratio (length-to-width ratio) and adding ribbed features. These parameter changes reduce the contact spring rate while maintaining the springs' ability to provide stable electrical connection under vibration and strain conditions.
Solution Approach 2:
The contact springs incorporate curved or arcuate geometries with specific radii of curvature. The curved design allows the springs to deflect more easily during insertion while maintaining contact pressure, thereby reducing insertion force while preserving connection reliability under adverse conditions.
2Ease of operation
If the contact spring rate is reduced, then the insertion force is lowered, but the control over contact normal force becomes less precise
Solution Approach 1:
The contact springs are segmented with ribbed features that create multiple discrete contact zones along the spring length. This segmentation allows each rib to contribute to the overall contact force, providing more predictable and controllable normal force even with reduced spring rate, while the segmented structure also increases deflection capability.
3Ease of operation
If the aspect ratio of contact springs is increased, then deflection is improved, but the structural stability may be compromised
Solution Approach 1:
The longer aspect ratio contact springs incorporate curved or arcuate geometries with specific radii of curvature. The curved design allows the springs to deflect more easily during insertion while maintaining contact pressure, thereby reducing insertion force while preserving connection reliability under adverse conditions.
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 achieves a lower insertion force during mating while ensuring a reliable and stable electrical connection, even under conditions of vibration, by accurately controlling the contact normal force and distributing forces effectively.
Implementation Method 1
Each of the at least two resilient arms generates a contact force when a mating terminal is inserted into the terminal
Data Source
AI summary
A terminal with ribbed contact springs for receipt of a mating terminal therein. The receptacle terminal has a contact portion which includes a bottom wall with contact sections extending from opposed sides of the bottom wall. Each of the contact sections have at least two resilient arms which extend from the bottom wall to a mating terminal engagement member. The at least two resilient arms have arcuate portions which extend from the bottom wall to the mating terminal engaging members. Each of the at least two resilient arms has a reduced contact spring rate, thereby allowing the contact normal force to be more accurately controlled with the same manufacturing tolerances. More controlled normal force allows for a minimum contact normal force to be reliably maintained while reducing the insertion force required during mating.