Segmented Terminal Contact Structure for Low Insertion Load
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Solution Overview
Problem
Existing terminal connection structures face challenges in maintaining a large contact area while minimizing insertion load when high electric currents are conducted, leading to increased heat generation and insertion resistance.
Innovation Solution
A terminal connection structure with a contact member featuring first and second contact portions elastically deformed in a radial direction, positioned differently along the axial direction, to increase contact area without significantly increasing insertion load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the contact member is enlarged in the axial direction to increase the contact area, then the heat generation of the contact member is reduced, but the insertion load increases
Solution Approach 1:
The contact member is divided into multiple contact portions (first contact portion and second contact portion) that are positioned at different axial locations. This segmentation allows the contact area to be distributed across different positions, increasing the total contact area for heat dissipation while each individual contact portion can deform independently, preventing simultaneous deformation across the entire length and thus reducing the insertion load.
2Reliability
If the contact area of the contact member is increased to restrain heat generation, then the electrical connectivity is improved, but the insertion resistance increases
Solution Approach 1:
The contact member is segmented into multiple contact portions positioned at different axial locations, which increases the total contact area for better electrical connectivity and heat dissipation. The segmented structure allows each contact portion to deform independently during insertion, reducing the peak insertion resistance compared to a single continuous contact member of the same total area.
3Temperature
If the contact member is enlarged to increase contact area, then the heat dissipation is improved, but the elastic deformation range increases
Solution Approach 1:
The contact member is divided into multiple separate contact portions along the axial direction. This segmentation increases the total contact area for heat dissipation while limiting the elastic deformation range of each individual contact portion. Since each contact portion deforms independently over a shorter axial distance, the overall elastic deformation range is reduced compared to a single enlarged contact member.
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 solution effectively stabilizes the contact and reduces insertion resistance while maintaining a large contact area, ensuring efficient electrical connectivity and heat management.
Implementation Method 1
The contact member includes a first contact portion and a second contact portion that are elastically deformed in a radial direction perpendicular to the axial direction
Data Source
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AI summary
A terminal connection structure (10) includes: a column-shaped male terminal (12) that extends in an axial direction (D1); a female terminal (14) that demarcates a hole (14h) into which the male terminal (12) is inserted; and at least one contact member (20, 120; 220) that is sandwiched between an outer side surface (12a) of the male terminal (12) and an inner side surface (14a) of the female terminal (14) and that electrically connects the male terminal (12) and the female terminal (14). The contact member (20, 120; 220) includes a first contact portion (26a) and a second contact portion (26b; 126b) that are elastically deformed in a radial direction (D2) perpendicular to the axial direction (D1), and the first contact portion (26a) and the second contact portion (26b; 126b) are provided at different positions from each other in the axial direction (D1).