Spring-Loaded Terminal Connector for Controlled Contact Force
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Solution Overview
Problem
Existing connector terminal connection structures face issues with inconsistent tightening forces leading to inadequate electrical conduction or excessive load on peripheral components, and require laborious torque wrench management.
Innovation Solution
A connector design featuring a nut with a flange part, a spring with a first hole, and terminals with specific hole shapes, allowing for a predetermined gap to achieve appropriate contact force without tools like a torque wrench.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a prior-art bolt fastening structure is applied to connector terminals, then the structure is simple, but the tightening force is either too weak for adequate electrical conduction or too strong causing extra load on peripheral components
Solution Approach 1:
The patent changes the physical parameters of the fastening components by specifying precise dimensional relationships: the hole shape in the second terminal has a size between the nut part outer shape and threaded hole shape, and a predetermined gap is established between the nut part and second terminal. These parameter changes enable the structure to self-regulate tightening force, achieving reliable electrical conduction without excessive load on peripheral components.
Solution Approach 2:
The patent introduces an intermediary geometric constraint through the hole shape design and predetermined gap. This intermediary structure mediates between the nut part and second terminal, controlling the tightening force transmission and preventing both insufficient and excessive compression, thereby ensuring reliable electrical conduction while protecting peripheral components.
2Reliability
If a torque wrench is used to achieve proper tightening force, then the contact force is controlled, but separate tool preparation and laborious management are required
Solution Approach 1:
The patent implements a self-service fastening mechanism where the predetermined gap and hole shape geometry automatically control the tightening force. The structure itself provides the control function that would otherwise require an external torque wrench, eliminating the need for separate tool preparation and laborious torque management while ensuring reliable contact force.
Solution Approach 2:
The patent performs preliminary action by pre-establishing the predetermined gap and designing the hole shape dimensions before assembly. This preliminary geometric configuration ensures that during assembly, the tightening force is automatically controlled without requiring real-time measurement or adjustment tools, simplifying the operation while maintaining reliability.
3Ease of operation
If terminals are tightened with insufficient force, then assembly is easy, but adequate electrical conduction cannot be achieved
Solution Approach 1:
The patent changes the geometric parameters by designing the hole shape with specific dimensions and establishing a predetermined gap. This parameter design ensures that during assembly, sufficient compression force is generated to achieve adequate electrical conduction, while the assembly process remains simple without requiring complex tools or procedures.
4Reliability
If terminals are tightened with excessive force, then electrical conduction is good, but extra load is applied to peripheral components such as insulators
Solution Approach 1:
The patent introduces an intermediary geometric constraint through the hole shape and predetermined gap design. This intermediary structure acts as a mechanical limiter that prevents excessive compression force from being transmitted to peripheral components like insulators, while still ensuring sufficient force for good electrical conduction between terminals.
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
Ensures sufficient electrical conduction with controlled contact force, minimizing load on components, and simplifies assembly by eliminating the need for torque wrenches.
Implementation Method 1
a spring (23) having a first hole part (232) into which the nut part (221) is insertable, the spring (23) being mounted on the flange part (222) by inserting the nut part (221) from the one end (221a) into the first hole part (232)
Data Source
AI summary
A connector includes a nut, a disc spring, a first terminal, and a second terminal. The disc spring is mounted on a flange part by inserting a nut part from an end into a first hole part. The first terminal is mounted on the disc spring by inserting the nut part from the end into a second hole part. The second terminal includes a third hole part having a hole shape smaller than an outer shape of the nut part and larger than a threaded hole shape of the nut and is mounted on the first terminal with the third hole part opposite to the second hole part. The connector is configured to provide a gap between the end and the second terminal, when the second terminal is mounted on the first terminal before the nut part is engaged with a threaded part.