Electrical Terminal Coil Spring Retention Design
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Solution Overview
Problem
Electrical terminals face connectivity issues due to poor contact caused by tolerance variations and degradation from repeated use, leading to loose or insecure mating arrangements between terminals and connectors.
Innovation Solution
An electrical terminal design featuring a recessed end with a resilient conducting element and an end cap to secure the coil spring, providing an interference fit and enhanced retention force, ensuring stable connectivity despite tolerance variations and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resilient conducting element is used to maintain electrical connectivity, then the electrical connection reliability is improved, but the device complexity increases due to additional components needed to secure the spring
Solution Approach 1:
The end cap is positioned within the recessed end of the terminal body, creating a nested structure where the cap is housed inside the terminal. This nesting approach secures the resilient conducting element without requiring external mounting structures, thereby maintaining reliability while minimizing added complexity.
Solution Approach 2:
The resilient conducting element automatically maintains electrical connectivity through its inherent spring force, requiring no additional actuation or control mechanisms. The element self-adjusts to accommodate tolerance variations and degradation, providing reliable connection without complex control systems.
2Strength
If an end cap is added to secure the coil spring, then the retention force is improved, but the manufacturing complexity increases
Solution Approach 1:
The terminal is divided into distinct functional segments: the terminal body, the resilient conducting element, and the end cap. This segmentation allows each component to be manufactured independently using standard processes, then assembled through simple insertion, improving retention force without significantly complicating manufacturing.
Solution Approach 2:
Instead of securing the spring from the exterior, the end cap approaches the spring from the interior recessed end. This inverted approach allows the cap to be inserted and seated against the spring, creating secure retention through a simple interference fit that is easy to manufacture and assemble.
3Stability of the object's composition
If the resilient conducting element is positioned within a recessed end, then the connectivity stability is improved, but the device complexity increases
Solution Approach 1:
The recessed end creates a nested configuration where the resilient conducting element is housed within the terminal body. This nesting provides stable positioning and protection for the conducting element, ensuring consistent electrical connectivity without requiring external support structures or complex mounting mechanisms.
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 ensures reliable and secure electrical connectivity by maintaining the spring's resilience and preventing loose connections, even with repeated use, through the use of a cap to compress and position the coil spring effectively.
Implementation Method 1
A spring is positioned within the open end and is configured to facilitate electrical connectivity between the body portion and the connector
Implementation Method 2
A coil spring is positioned within the first cylindrical receptacle. The coil spring is configured to facilitate electrical connectivity
Implementation Method 3
The conducting element has a first opening with a second width to provide an interference fit with a connector received within the resilient conducting element
Data Source
AI summary
An electrical terminal is operable to facilitate electrical connectivity between the terminal and an electrical connector. The electrical terminal may include a cap to facilitate positioning a conducting element, such as but not limited to a coil spring, within a receptacle used to connect to an electrically conducting connector. The conducting element may facilitate electrical connectivity between the inserted connector and the terminal.