Electrical Terminal Assembly With Steel Spring Clamp
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Solution Overview
Problem
Copper electrical terminals in high power vehicle connectors experience a loss of spring force due to temperature increase, leading to reduced electrical conductivity and increased resistance, which is challenging to address within size limitations.
Innovation Solution
A two-piece electrical terminal assembly featuring a base with opposed beams and a spring clamp made of high-yield strength material, where the spring clamp is assembled onto the base in a back-loaded manner with a locking feature to prevent lateral movement, ensuring consistent clamping force over a wide temperature range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper terminals are used for good electrical conductivity, then electrical conductivity is improved, but spring force is lost at high temperatures
Solution Approach 1:
The terminal is divided into two separate components: a copper base providing electrical conductivity and a steel spring clamp providing spring force. Each component is made from material optimized for its specific function, allowing the copper base to maintain conductivity while the steel clamp maintains spring force at high temperatures.
Solution Approach 2:
The terminal assembly combines two different materials (copper and steel) into a composite structure. The copper base and steel spring clamp work together to provide both electrical conductivity and temperature-resistant spring force, overcoming the limitations of using a single material.
2Strength
If terminal size is increased to maintain spring force, then spring force is improved, but connector size increases
Solution Approach 1:
The invention changes the material parameter of the spring clamp from copper to high-yield-strength steel, allowing the same clamping force to be achieved with a smaller cross-sectional area and volume, thus reducing overall connector size while maintaining spring force.
3Reliability
If copper terminals are used, then electrical conductivity is improved, but resistance increases at high temperatures
Solution Approach 1:
By separating the electrical conduction function (copper base) from the spring force function (steel clamp), the design allows the copper base to maintain optimal conductivity while the steel clamp provides thermal stability, reducing the overall temperature effect on terminal performance.
4Strength
If spring clamp is made of steel with high yield strength, then spring force is maintained at high temperatures, but material cost increases
Solution Approach 1:
The invention applies high-yield-strength steel only to the spring clamp portion where spring force is needed, while the base remains copper for conductivity. This localized use of expensive material minimizes cost while achieving the required performance.
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 assembly maintains strong clamping force and electrical conductivity across varying temperatures, reducing the overall size of the connector while maintaining high current-carrying capacity, thus addressing the limitations of copper terminals.
Implementation Method 1
a spring clamp made of a suitable material, such as steel, having a high yield strength or spring-like quality
Data Source
AI summary
An electrical assembly includes a base having a body including a first end and a second end. First and second opposed base beams extend from the first end of the body in a first direction. The assembly further includes a spring clamp having a clamp base and first and second opposed spring beams extending from the clamp base in the first direction and disposed over the first and second base beams biasing the first and second base beams towards one another. The spring clamp is assembled onto the base by moving the spring clamp along the first direction onto the base. A locking feature is integrally formed in the base and the spring clamp preventing the removal of the spring clamp from the base along a second direction opposite the first direction. The locking feature also prevents movement of the spring clamp relative to the base in a lateral direction normal to the first direction.