Electrical Terminal With Copper Core Reduces Cost
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Solution Overview
Problem
Conventional electrical contact terminals have a high and variable cost due to the use of copper, which affects the profitability of manufacturers and sellers.
Innovation Solution
The design incorporates a low-cost, low-conductivity body made of materials like stainless steel and a high-conductivity copper core, where the copper core is used only in an uninterrupted direct path from the contact to the crimp, minimizing material usage and scrap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper is used to manufacture traditional electrical terminals, then high conductivity is achieved, but material cost becomes high and variable
Solution Approach 1:
The terminal is divided into two distinct members: a first member made of lower-cost material and a second member made of high-conductivity copper. This segmentation allows each material to be used only where necessary - the copper member for electrical conduction paths and the first member for structural functions - thereby reducing overall copper usage while maintaining conductivity performance.
Solution Approach 2:
The terminal employs a composite structure combining two different materials with complementary properties. The first member provides mechanical strength and structural support, while the second copper member provides high electrical conductivity. This composite approach optimizes both electrical performance and cost efficiency by matching material properties to functional requirements.
2Reliability
If copper is used throughout the terminal, then conductivity is maintained, but the amount of copper and scrap increases
Solution Approach 1:
The copper material is extracted from the entire terminal structure and confined only to the second member that forms the electrical conduction path. By removing copper from non-essential areas and using it only where conductivity is critical, the design minimizes copper consumption and reduces scrap generation while preserving necessary electrical performance.
Solution Approach 2:
High-conductivity copper material is applied locally only where electrical conduction is required (in the second member), rather than uniformly throughout the entire terminal. This localized material distribution ensures optimal conductivity in critical areas while reducing overall copper usage and associated scrap.
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
This approach reduces the overall cost of the terminal while maintaining high conductivity, allowing for independent variation of the copper core thickness and plating without affecting the terminal body material, thereby enhancing profitability and system conduction.
Implementation Method 1
The second member is made from a material which is more conductive than material of the first member. The second member includes a front end configured to electrically contact an opposite second side of the mating contact and a rear end configured to attach to the electrical conductor.
Data Source
AI summary
An electrical terminal including a first member and a second member. The first member has a front end configured to receive a mating contact and a rear end configured to attach to an electrical conductor. The first member is adapted to contact a first side of the mating contact. The second member is located, at least partially, in the first member. The second member is made from a material which is more conductive than material of the first member. The second member includes a front end configured to electrically contact an opposite second side of the mating contact and a rear end configured to attach to the electrical conductor.