Terminal Module Orthogonal Contact Guide for Foreign Substance Removal
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Solution Overview
Problem
Existing terminal modules fail to effectively remove foreign substances between contact points, especially in large-current applications where the thickness of the leaf spring becomes too rigid, preventing resilient deformation and sliding, which is necessary for foreign substance elimination.
Innovation Solution
A terminal module with a case containing a resilient member that biases an electrical contact, guiding it orthogonally when pressed by a mating contact point, using first and second guides to ensure uniform friction and repeated cleaning of foreign substances without requiring resilient deformation of the electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of the leaf spring is increased to enhance rigidity for large-current applications, then the current carrying capacity is improved, but the leaf spring cannot be deformed resiliently and sliding cannot occur, preventing foreign substance elimination
Solution Approach 1:
The invention divides the contact establishment process into two independent functions: (1) the resilient member provides elastic force to push the electrical contact toward the contact point, and (2) the guide portions enable orthogonal sliding movement to eliminate foreign substances. This segmentation allows the electrical contact to be designed with sufficient thickness for current carrying without requiring resilient deformation of the contact itself.
Solution Approach 2:
The guide portions act as an intermediary mechanism between the electrical contact and the contact point. They convert the linear movement caused by resilient member compression into orthogonal sliding movement, enabling foreign substance elimination without requiring the electrical contact itself to deform resiliently.
2Object-affected harmful factors
If the electrical contact is designed to slide and deform resiliently to scrape off foreign substances, then foreign substance elimination is achieved, but the plate thickness must be reduced which limits current carrying capacity
Solution Approach 1:
The invention separates the foreign substance elimination function from the current carrying function by using the guide portions for sliding movement and allowing the electrical contact to maintain sufficient thickness for current carrying without requiring resilient deformation.
Solution Approach 2:
The invention replaces the traditional resilient deformation mechanism with a guide-based orthogonal sliding mechanism. Instead of relying on the electrical contact to deform and spring back for scraping, the guide portions constrain and direct the sliding movement to achieve foreign substance elimination.
3Manufacturing precision
If the electrical contact is guided linearly to an oblique front side, then uniform friction is achieved during shifting, but the guide structure becomes more complex
Solution Approach 1:
The guide portions are integrated with the case structure, merging the guiding function into the existing housing rather than adding separate external guide components. This reduces overall device complexity while achieving the desired oblique linear guidance for uniform friction distribution.
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
Enables effective removal of foreign substances even with increased current values and plate thickness, preventing fretting wear and maintaining consistent electrical resistance by guiding the electrical contact to shifted positions for uniform scraping and return to initial positions.
Implementation Method 1
A resilient member 16 is accommodated in the case 52, and an electrical contact 53 is biased toward the opening 52A by the resilient member 16
Implementation Method 2
the electrical contact member is guided to the position shifted from the position before the movement in the direction orthogonal to the inserting direction of the mating contact point. Thus, a shifting phenomenon occurs so that the mating contact point rubs the electrical contact. Thus, any foreign substances that adhere to a surface of the electrical contact member to be contacted by the mating contact point and any foreign substances that adhere to the mating contact point are scraped off
Data Source
AI summary
A terminal fitting (50) includes a metal case (52) having an opening (52A) through which a mating contact point (31) is inserted, a coil spring (16) accommodated in the metal case (52), and an electrical contact (53) biased toward the opening (52A) by the coil spring (16) and configured to move while compressing the coil spring (16) by being pressed by the mating contact point (31). The metal case (52) includes a first guide (parts at both front and rear sides of an opening (57) in a front wall (55) of the metal case (52)) configured to guide the electrical contact (53) to a position shifted from a position before a movement in a direction orthogonal to an inserting direction of the mating contact point (31) by sliding in contact with the electrical contact (53) when the electrical contact (53) moves by being pressed by the mating contact point (31).