Terminal Module Obliquely Wound Coil Spring Holder
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Solution Overview
Problem
Existing terminal module and connector configurations require complex manufacturing processes and are prone to assembly tolerances and vibration issues due to the need for precise grooves and welding, which complicates the electrical connection and can lead to plastic deformation.
Innovation Solution
A terminal module with a conductive obliquely wound coil spring held by a holder that includes a displacement restricting portion and an engaging portion, allowing the holder to be displaceable and preventing excessive spring compression, while maintaining a simple configuration and manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a groove is provided in the conductor by cutting and welding both ends of the spring contact to the conductors, then the spring contact can be securely attached, but the configuration and manufacturing process become complicated
Solution Approach 1:
The invention extracts the spring contact from the groove structure and eliminates the welding process. The spring contact is directly inserted into the holder body without requiring grooves or welding, thereby simplifying the configuration and manufacturing process while maintaining secure attachment through the holder's retaining structure
Solution Approach 2:
The holder is divided into distinct functional portions: a holder body for receiving the spring contact, and a retaining portion for securing it. This segmentation allows the spring contact to be attached through simple insertion without complex assembly operations like welding or groove formation
2Device complexity
If the holder body is fixed without displacement capability, then the structure is simpler, but assembling tolerances and vibrations affect electrical connection and contact resistance
Solution Approach 1:
The holder body is designed with displacement capability in the direction toward and away from the coil holding surface, transforming the static holder into a dynamic component. This allows the holder to absorb assembling tolerances and vibrations through controlled movement, maintaining stable electrical connection without increasing overall structural complexity
3Reliability
If the holder body is made displaceable to absorb tolerances, then electrical connection stability improves, but the spring may be excessively compressed causing plastic deformation
Solution Approach 1:
The holder body's displacement capability is designed to be dynamic and controlled, allowing it to move toward the coil holding surface to absorb tolerances and vibrations, while the displacement restricting portion prevents excessive compression that would cause plastic deformation of the spring
Solution Approach 2:
The displacement restricting portion changes the displacement parameter of the holder body by providing a physical stop. This ensures the holder can move sufficiently to absorb assembling tolerances and vibrations, but prevents movement beyond a safe limit that would excessively compress the spring and cause plastic deformation
4Strength
If welding is used to attach the spring contact to the conductors, then the connection is strong, but the manufacturing process becomes complicated and time-consuming
Solution Approach 1:
The invention extracts the welding process from the assembly method. The spring contact is attached to the conductors through direct insertion into the holder body without welding, eliminating the complex and time-consuming welding operation while maintaining strong electrical connection through the holder's retaining structure
Solution Approach 2:
The holder body is pre-formed with the retaining portion and opening configured to receive and secure the spring contact. This preliminary preparation allows the spring contact to be attached through simple insertion without requiring subsequent welding or other complex finishing operations, significantly improving manufacturing efficiency
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 absorbs assembly tolerances and vibrations without affecting electrical connection, reduces contact resistance, and prevents plastic deformation of the coil spring, ensuring reliable and stable connections.
Implementation Method 1
the obliquely wound coil spring has a nonlinear region where a spring load hardly changes even if a height (dimension in a direction perpendicular to a coil axis) of the spring is changed
Data Source
AI summary
A terminal module (10) includes an electrical contact member (11) having a coil holding surface (12F) configured to face a contact surface (62F) provided on a mating terminal (61), a conductive obliquely wound coil spring (21) and a holder (31) configured to hold the obliquely wound coil spring (21) by being assembled with the electrical contact member (11). The holder (31) includes a holder body (32) configured to hold the obliquely wound coil spring (21) along the coil holding surface (12F) and having a window portion (35) configured to expose the obliquely wound coil spring (21) toward a side opposite to the coil holding surface (12F), and locking pieces (39) continuous from the holder body (32) and configured to engage the electrical contact member (11).