Spring Contact Connector Assembly for Stable High-Voltage Coupling
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Solution Overview
Problem
Connector assemblies with copper alloy terminals face issues of unstable contact and increased contact resistance due to plastic deformation and fretting wear under severe conditions, leading to quality problems and potential safety hazards, especially in high-voltage applications.
Innovation Solution
A connector assembly design featuring a female connector with a pair of female terminals and a male connector with a male terminal guide, where the female terminal is fixed on one end and extends by a predetermined length, and a release prevention lever is used to maintain contact stability and facilitate reworking, utilizing a copper alloy with high spring characteristics and a coil spring or leaf spring design to reduce deformation and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper alloy terminals with spring characteristics are used for contact, then electrical signal transmission is enabled, but plastic deformation occurs under severe conditions leading to unstable contact and increased contact resistance
Solution Approach 1:
The patent changes the material parameter from conventional copper alloy to beryllium copper alloy, which has superior elastic properties and resistance to plastic deformation. This material parameter change enables the terminal to maintain stable contact under severe conditions including impact, vibration, and heat without the plastic deformation that plagues conventional copper alloys.
2Reliability
If plated terminals are used for connection, then electrical contact is established, but fretting wear occurs due to tolerance management difficulties leading to increased contact resistance
Solution Approach 1:
The patent changes the material parameter to beryllium copper alloy which inherently provides better dimensional stability and tolerance control compared to conventional copper alloys. This reduces the difficulty of tolerance management during assembly and minimizes fretting wear between mated connectors, thereby maintaining low contact resistance over time.
3Reliability
If connector structures are designed to improve coupling durability, then contact stability under severe conditions is enhanced, but reworking and re-engagement become difficult
Solution Approach 1:
The patent segments the connector into distinct components: a housing, a female connector assembly with female terminals, and a male connector assembly with male terminals. This segmentation allows each component to be independently manufactured, tested, and replaced if necessary, facilitating reworking and re-engagement while maintaining overall coupling durability through the robust beryllium copper alloy terminals.
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 prevents poor contact issues and fretting wear, maintains low resistance, and allows for easy reworking without damaging the terminals, enhancing durability and safety by ensuring multiple contact points and adjustable engagement through elastic modulus and shape.
Implementation Method 1
a female terminal made of beryllium copper alloy, which is different from a conventional copper alloy, has a spring characteristic
Implementation Method 2
utilizing a copper alloy with high spring characteristics and a coil spring or leaf spring design to reduce deformation and wear
Data Source
AI summary
A connector assembly includes a female connector having a pair of female terminals inserted into a housing of which one side is open, and including a male connector having a male terminal inserted between the pair of female terminals to come into contact with the pair of female terminals. one end of a female terminal of the pair of female terminals is fixed to an inner surface of the housing. The other end thereof is disposed to extend by a predetermined length. A displacement of the other end occurs toward the one end due to the configuration of the male connector. A contact defect problem during coupling does not occur and reworking of the connector assembly is facilitated.