Electrical Terminal with Symmetrical Spring Shroud

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing female electrical terminals lack effective front end protection during shipping, handling, and use, and there is a need for improved designs that maintain compression force and conductivity while preventing damage to contact arms.

Innovation Solution

A female electrical terminal with a symmetrical spring member that includes a shroud extending around and beyond the contact arms, providing side and end protection, and is made from materials with good electrical conductivity and spring characteristics, such as copper and stainless steel, respectively.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a spring member is added to maintain compression force, then contact reliability is improved, but device complexity increases

Engineering Contradiction:

Improvecontact reliabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The shroud is integrated with the spring member to form a single component, combining the protection function with the compression force maintenance function. This eliminates the need for separate protection pieces while maintaining contact reliability through the spring mechanism.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The spring member is designed to perform multiple functions: maintaining compression force on contact arms and providing protective enclosure through the integrated shroud. This multi-functional design reduces overall device complexity while improving reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If front end protection is added to protect contact arms, then durability is improved, but device complexity increases

Engineering Contradiction:

ImprovedurabilityVSAvoiddevice complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The shroud is merged with the spring member into a single integrated component, providing protection for contact arms during shipping and handling without requiring additional separate protection pieces. This integration maintains durability while minimizing device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The shroud functions as a protective shell extending around the contact arms, providing durable protection against damage during shipping, handling, and installation while maintaining a relatively simple structural form.

Inventive Principle:

Principle #30Flexible shells and thin films

3Stability of the object's composition

If spring material with inferior electrical conductivity is used, then spring characteristics are improved, but electrical conductivity deteriorates

Engineering Contradiction:

Improvespring characteristicsVSAvoidelectrical conductivity

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The electrical terminal is divided into distinct functional segments: the contact portion made of highly conductive material for electrical connection, and the spring member made of material with superior spring characteristics. This segmentation allows each component to be optimized for its specific function without compromise.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different materials are used in different locations based on functional requirements: copper or copper alloy for the contact portion where electrical conductivity is critical, and stainless steel or phosphor bronze for the spring member where mechanical spring characteristics are critical. This local quality optimization resolves the contradiction between conductivity and spring characteristics.

Inventive Principle:

Principle #3Local quality

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 maintains compression force and protects the contact arms from damage, ensuring reliable electrical connections and durability across varying temperatures.

Implementation Method 1

The spring member is typically made of a material that, compared to the material of the contact portion, has inferior electrical conductivity but is less susceptible to relaxation. The spring maintains the desired compression force

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

The shroud is connected to the spring base and extends around the contact arms and beyond the contact arms

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Implementation Method 3

Female terminals often include a contact portion with multiple contact arms that press onto sides of the male terminal

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS10283889B2Electrical terminal with balanced front end protection

Publication Date: 2019.05.07 LEAR CORP

AI summary

An electrical terminal includes a contact member. The contact member includes a contact base. The contact member includes a plurality of contact arms extending from the contact base. The contact arms are arranged on opposed sides of a terminal plane. The electrical terminal also includes a spring member. The spring member includes a spring base. The spring member includes a plurality of spring arms. The spring arms extend from the spring base. Each of the spring arms engages one or more of the contact arms. The spring member also includes a shroud. The shroud is connected to the spring base and extends around the contact arms and beyond the contact arms. The spring member is symmetrical across the terminal plane.