Staggered Electrical Connector Terminals Reduce Mating Force
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Solution Overview
Problem
Existing electrical connection systems require high engagement forces to mate male and female connectors, necessitating auxiliary mechanical devices that increase complexity, cost, and size, particularly in space-constrained environments.
Innovation Solution
The electrical connection system employs a staggered arrangement of male and female terminal tips, reducing the peak engagement force by distributing it over a wider range of motion, allowing for a higher number of terminals to be connected with a given force, potentially eliminating the need for auxiliary mechanical devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If all male blade terminals are positioned at the same height to mate simultaneously, then the electrical connection is achieved, but the engagement force required becomes excessively high (several hundred newtons)
Solution Approach 1:
The patent divides the male blade terminals into multiple height groups (first population at first height, second population at second height). This segmentation allows terminals to engage sequentially rather than simultaneously, distributing the engagement force over time and reducing the peak force required to mate the connectors.
Solution Approach 2:
The staggered arrangement performs preliminary engagement action by having shorter terminals engage first, establishing initial contact before longer terminals engage. This progressive engagement sequence reduces the sudden force spike that would occur with simultaneous engagement of all terminals.
2Force
If auxiliary mechanical devices (bolt fastener or lever mechanism) are added to reduce engagement force, then the connectors can be mated with lower force, but the device complexity and manufacturing cost increase
Solution Approach 1:
The staggered terminal arrangement enables the connector system to self-regulate engagement force through its geometric configuration. The varying terminal heights automatically create a progressive engagement sequence that limits peak force to ergonomic levels, eliminating the need for external mechanical assistance devices.
Solution Approach 2:
The patent changes the spatial parameter of terminal positioning from uniform height to staggered heights. This parameter modification fundamentally alters the engagement mechanics, reducing peak force requirements without adding mechanical complexity, as the geometric arrangement itself provides the force-distributing mechanism.
3Force
If auxiliary mechanical devices are added to assist mating, then the engagement force is reduced, but the overall size of the electrical connection system increases
Solution Approach 1:
The patent extracts and eliminates the need for auxiliary mechanical devices (bolts, levers, fasteners) by incorporating the force-reduction function directly into the terminal arrangement. This extraction removes unnecessary components, reducing overall system size while maintaining the benefit of reduced engagement force.
4Quantity of substance
If a higher number of male blade terminals are included in each connector, then the electrical distribution capability is improved, but the engagement force required to mate the connectors increases
Solution Approach 1:
By segmenting terminals into height groups, the patent enables higher terminal counts without proportionally increasing engagement force. The sequential engagement of segmented groups allows multiple terminals to be accommodated while distributing the mechanical load over time, preventing force multiplication that would occur with simultaneous engagement.
Solution Approach 2:
The preliminary engagement of shorter terminals creates a staged connection process that allows additional terminals to be incorporated into the connector design without linearly increasing peak force requirements. Each height group engages in sequence, enabling scalable terminal counts within ergonomic force limits.
Data Source
AI summary
An electrical connection system comprises a female connector having a plurality of female terminals, and a male connector having a plurality of male blade terminals having projecting portions that plug into the plurality of female terminals respectively when the female connector and the male connector are mated. The male blade terminals are staggered having a first population with their tips at a first relative position and a second population with their at a second different relative position so that the first tips and the second tips do not touch and fully engage the mating female terminals and the plurality of male blade terminals at the same time thereby lowering the peak engagement force required for mating the female connector and the male connector. In an alternative arrangement, the female terminals, rather than the male blade terminals are staggered.