Terminal Contact Structure for Low-Load High-Current Connection

Solution Overview

Problem

Existing terminal connection structures face challenges in maintaining a large contact area while minimizing the insertion load when a large electric current flows, leading to increased heat generation and insertion resistance.

Innovation Solution

A terminal connection structure with a contact member featuring first and second contact portions elastically deformed in a radial direction, positioned differently along the axial direction, to stabilize the contact and reduce insertion load.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the contact member is enlarged in the axial direction to increase the contact area, then the heat generation is restrained, but the insertion load increases

Engineering Contradiction:

Improveheat generationVSAvoidinsertion load

Core Design Contradiction:

TemperatureVSForce

Solution Approach 1:

The contact member is divided into multiple contact portions (first contact portion and second contact portion) that are positioned at different axial locations. This segmentation allows the contact area to be increased through multiple distributed contact points rather than a single large axial extension, thereby reducing the insertion load while maintaining adequate contact area for heat dissipation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of increasing the contact area solely in the axial direction, the invention utilizes the radial direction by elastically deforming the contact portions radially outward. This dimensional shift allows the contact portions to engage with the male terminal at different radial positions, increasing the effective contact area without requiring proportional axial length increase, thus reducing insertion resistance.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If the contact member is enlarged in the axial direction to increase the contact area, then the electrical connection is improved, but the insertion resistance increases

Engineering Contradiction:

Improveelectrical connectionVSAvoidinsertion resistance

Core Design Contradiction:

ReliabilityVSForce

Solution Approach 1:

The contact member is divided into multiple contact portions (first contact portion and second contact portion) that are positioned at different axial locations. This segmentation allows the contact area to be increased through multiple distributed contact points rather than a single large axial extension, thereby reducing the insertion load while maintaining adequate contact area for heat dissipation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of increasing the contact area solely in the axial direction, the invention utilizes the radial direction by elastically deforming the contact portions radially outward. This dimensional shift allows the contact portions to engage with the male terminal at different radial positions, increasing the effective contact area without requiring proportional axial length increase, thus reducing insertion resistance.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 effectively increases the contact area without significantly increasing insertion load, maintaining stable electrical connections and reducing heat generation in high-current applications.

Implementation Method 1

The contact member includes a first contact portion and a second contact portion that are elastically deformed in a radial direction perpendicular to the axial direction

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS20250219311A1Terminal connection structure

Publication Date: 2025.07.03 TOYOTA JIDOSHA KK

AI summary

A terminal connection structure includes: a column-shaped male terminal that extends in an axial direction; a female terminal that demarcates a hole into which the male terminal is inserted; and at least one contact member that is sandwiched between an outer side surface of the male terminal and an inner side surface of the female terminal and that electrically connects the male terminal and the female terminal. The contact member includes a first contact portion and a second contact portion that are elastically deformed in a radial direction perpendicular to the axial direction, and the first contact portion and the second contact portion are provided at different positions from each other in the axial direction.