Stamped Cylindrical Power Terminal for Low-Force High-Current Mating
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Solution Overview
Problem
Conventional power connectors face challenges in achieving high current transmission while enduring a large number of mating cycles without excessive wear and high manufacturing costs, often requiring high contact force that leads to reduced lifespan and increased costs due to machined pins.
Innovation Solution
The development of power terminals formed from a single stamped metal sheet with deflectable beams, configured to provide low contact force and high current carrying capacity, using selective plating and optimized geometries to reduce wear and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional machined pins are used to achieve high current transmission, then current carrying capacity is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent changes the manufacturing method from traditional machining to stamping process, transforming the production parameters. The stamped metal sheet terminal maintains high current carrying capacity while significantly reducing manufacturing cost and complexity. The stamping process allows for high-volume production with consistent electrical properties.
Solution Approach 2:
The patent employs composite construction by combining metal sheet material with selective plating (such as copper, brass, or other conductive materials). This composite approach creates a terminal that combines the structural integrity of stamped metal with the superior electrical conductivity of plated surfaces, achieving both cost-effectiveness and high current transmission capability.
2Reliability
If high contact force is applied to ensure reliable electrical connection, then connection reliability is improved, but terminal lifespan decreases due to excessive wear
Solution Approach 1:
The patent applies local quality by implementing selective plating only on the contact surfaces of the terminal. This ensures that the critical mating surfaces have enhanced properties (lower contact resistance, reduced wear) while the rest of the terminal maintains its structural characteristics. The plated contact surfaces provide reliable electrical connection with reduced wear during repeated mating cycles.
Solution Approach 2:
The patent incorporates deflectable beams that provide dynamic contact force adjustment. These beams can flex to accommodate tolerance variations and maintain optimal contact pressure without excessive force. The dynamic deflection capability ensures reliable connection while preventing wear caused by overly rigid high-force contacts.
3Strength
If traditional manufacturing processes are used for power terminals, then structural integrity is maintained, but manufacturing cost and production time increase
Solution Approach 1:
The patent segments the terminal into distinct functional zones: the stamped metal sheet body providing structural integrity, and selectively plated contact surfaces providing electrical functionality. This segmentation allows each zone to be optimized independently - the stamping process for structural strength and the plating process for electrical performance - while enabling parallel manufacturing operations that improve overall productivity.
Solution Approach 2:
The patent replaces traditional mechanical machining processes with stamping and plating processes. The stamping process forms the terminal structure through controlled deformation rather than material removal, significantly reducing production time. The selective plating then applies conductive material only where needed, reducing material usage and post-processing requirements compared to traditional machining and plating of entire components.
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 enables power connectors to withstand 10,000 mating cycles with low contact resistance and high current transmission, while reducing wear and manufacturing costs through the use of stamped metal sheets and selective plating.
Implementation Method 1
Inserting the plug into the receptacle connector deflects beams of the sockets that press against the pins, generating a contact force that creates a low resistance path between the plug connector and the receptacle connector
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 1E~1G
AI summary
High current, light, and low-cost electrical power terminals that can withstand many mating cycles. A socket or a pin may be formed from a monolithic metal sheet, which may be stamped and formed into a terminal with a hollow portion, such as a cylindrical barrel. Features defining the radius of the barrel may be stamped in the sheet with high precision. The socket and the pin are shaped such that the positions of the mating contact surfaces of each terminal, and therefore the interference between them, are positioned based on these features. The terminals may have a low and precise interference, enabling the terminals to be designed with a low contact force that enables a long lifespan, such as 10,000 mating cycles. The terminals may have a high current capacity, such as 50 A or higher, and may be used in high current applications, such as a charging station or an electric vehicle, or in an application that calls for charging or discharging a battery.