Electrical Contact Spring Shroud Extension Stabilization
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Solution Overview
Problem
Existing female electrical terminals with springs face challenges in maintaining proper positioning and stability during assembly, especially when subjected to temperature changes and handling, which can affect the compression force and contact area with male terminals.
Innovation Solution
A spring member with a shroud that extends around and beyond the contact arms, featuring shroud extensions engaging multiple sides of the contact base for stabilization, ensuring secure positioning and maintaining compression force even at elevated temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a spring member is added to increase compression force, then the contact area is maintained, but the device complexity increases
Solution Approach 1:
The shroud extension is integrated with the spring member to form a single unified component. This merging of the shroud extension with the spring body eliminates the need for separate positioning features, thereby maintaining contact area stability while avoiding additional device complexity.
2Force
If the spring member is made less susceptible to relaxation, then the compression force is maintained, but the electrical conductivity deteriorates
Solution Approach 1:
The spring member is designed with localized engagement features (shroud extension engaging specific sides of the contact base) that concentrate the relaxation resistance function in specific areas. This allows the spring material to maintain compression force where needed while minimizing the impact on electrical conductivity paths in other areas.
3Reliability
If front end protection is added to protect contact arms, then the reliability is improved, but the ease of manufacture decreases
Solution Approach 1:
The shroud extension is formed as an integral part of the spring member through a single manufacturing process. This merging of the protective shroud extension with the spring body eliminates the need for separate assembly steps, thereby improving reliability through protection while maintaining ease of manufacture.
4Stability of the object's composition
If the spring member positioning is improved, then the stability is enhanced, but the device complexity increases
Solution Approach 1:
The shroud extension automatically positions itself by engaging with the sides of the contact base during assembly. This self-positioning mechanism eliminates the need for additional positioning features or adjustment mechanisms, thereby enhancing stability without increasing device 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
The solution enhances the stability and positioning of the spring member relative to the contact member, maintaining consistent compression force and contact area with male terminals across varying temperatures and handling conditions.
Implementation Method 1
The spring member is typically made of a material that, compared to the material of the contact portion, has inferior electrical conductivity but is less susceptible to relaxation. The spring maintains the desired compression force
Data Source
AI summary
An electrical terminal assembly includes a contact member. The contact member has a contact base. A plurality of contact arms extend from the contact base in an arm direction. The electrical terminal assembly includes a spring member supported on the contact member. The spring member includes a spring base. A plurality of spring arms extend from the spring base in the arm direction. The spring arms engage the plurality of contact arms. The spring member includes a shroud. The shroud extends in the arm direction around and beyond the contact arms. A shroud extension extends from the shroud opposite the arm direction. The shroud extension engages the contact base.