Terminal Insert Portion Arc Discharge and Deformation Control

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Solution Overview

Problem

Existing female-type metal terminal fittings lack an arc discharge contact point and a stable front frame latching structure, leading to electric sparks during hot plugging and deformation when the male terminal is obliquely inserted.

Innovation Solution

The connector features an insulating housing with a terminal receiving groove, an insert portion with a front frame, rear frame, top plate, arc discharge contact member, and primary contact member, including elastic arms that provide arc discharge protection and resistance to deformation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If the female-type metal terminal fitting uses a simple contact structure, then the device complexity is reduced, but arc discharge occurs during hot plugging and electric sparks are generated

Engineering Contradiction:
Improvecontact structure complexityVSAvoidarc discharge and electric sparks
Core Design Contradiction:
Device complexityVSObject-affected harmful factors

Solution Approach 1:

The contact structure is segmented into multiple contact points including a first contact point, second contact point, third contact point, and fourth contact point. These contact points are distributed across different locations on the terminal fitting, with the first and second contact points forming a first contact pair and the third and fourth contact points forming a second contact pair. This segmentation allows arc discharge to occur at dedicated sacrificial contact points (third and fourth) rather than at the primary contact points (first and second), protecting the main contacts while managing hot plugging effects.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The third contact point and fourth contact point act as intermediary sacrificial contact points that absorb the harmful arc discharge during hot plugging operations. These intermediary contacts are positioned to engage before the primary contacts, serving as a buffer that protects the main contact structure from damage while still enabling electrical connection functionality.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Ease of manufacture

If the female-type metal terminal fitting lacks a reinforced front frame structure, then the manufacturing complexity is reduced, but the terminal fitting deforms when the male terminal is obliquely inserted

Engineering Contradiction:
Improvemanufacturing complexityVSAvoidstructural stability during insertion
Core Design Contradiction:
Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The front frame structure employs asymmetric reinforcement with a first reinforcing rib and a second reinforcing rib positioned at different locations and orientations. The first reinforcing rib extends from the front end of the upper plate toward the first contact point, while the second reinforcing rib extends from the front end of the lower plate toward the second contact point. This asymmetric reinforcement pattern provides targeted structural support to prevent oblique insertion deformation while maintaining manufacturing feasibility.

Inventive Principle:
Principle #4Asymmetry

Solution Approach 2:

The reinforcing ribs add a third dimensional element to the otherwise planar terminal fitting structure. By extending ribs in the longitudinal direction from the front end plates toward the contact points, the structure gains enhanced stiffness and resistance to oblique forces without significantly increasing manufacturing complexity. This dimensional addition transforms a flat, deformable structure into a three-dimensionally reinforced framework.

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 design effectively controls arc discharge during hot plugging and prevents deformation by distributing contact points to minimize spark impact and ensure stable insertion, while the elastic arms enhance flexibility and resistance to fretting corrosion.

Implementation Method 1

the top contact portion and the bottom plate contact portion contact the male terminal earlier than the first contact point in the left and the second contact point in the right, so as to cause an arc discharge to occur only at the top contact portion in the up and the bottom plate contact portion in the down

Methodology Applied
Scientific EffectArc discharge: Electric Arc

Implementation Method 2

The top elastic arm extends from the rear frame portion to the front frame portion... The first elastic arm extends from the rear frame portion to the front frame portion... The second elastic arm extends from the rear frame portion to the front frame portion

Methodology Applied
Scientific EffectElasticity: Elasticity

Data Source

PatentUS11394153B2Connector and terminal
Publication Date: 2022.07.19 MOLEX INC
  • US11394153B2 patent drawing
  • US11394153B2 patent drawing
  • US11394153B2 patent drawing

AI summary

The present disclosure provides a connector and a terminal. The connector includes a terminal. The terminal includes an insert portion. The insert portion includes a front frame portion, a rear frame portion, a top plate portion, an arc discharge contact member and a primary contact member. The arc discharge contact member includes a bottom plate portion and a top elastic arm. The bottom plate portion connects the front frame portion and the rear frame portion and is spaced apart from the top plate portion in an up-down direction. The top elastic arm extends from the rear frame portion to the front frame portion and is positioned below the top plate portion. The arc discharge contact member is positioned in front of the primary contact member. The primary contact member includes a first elastic arm and a second elastic arm. The first elastic arm extends from the rear frame portion to the front frame portion and is adjacent between the bottom plate portion and the top elastic arm. The second elastic arm extends from the rear frame portion to the front frame portion, is adjacent between the top plate portion and the bottom plate portion, and spaced apart from the first elastic arm in a left-right direction.