Electrical Terminal Assembly with Segmented Spring Shroud
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Solution Overview
Problem
Existing electrical terminal assemblies have limited contact area with mating terminals, and existing solutions that use spring members for increased compression force often utilize materials with inferior electrical conductivity.
Innovation Solution
The electrical terminal assembly features a contact member with multiple contact arms and a spring member that includes a shroud with end and side shields, providing a larger contact area and additional strength without increasing size, and includes terminal guides to protect the contact arms during mating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a spring member is added to increase compression force, then the contact area is maintained, but the electrical conductivity deteriorates due to inferior material properties
Solution Approach 1:
The spring member is segmented into multiple spring arms (first, second, third, and fourth spring arms) that can independently engage with contact arms. This segmentation allows the spring member to distribute compression force across multiple contact points while maintaining overall electrical conductivity through the distributed contact paths.
Solution Approach 2:
The spring member extends in multiple directions (first direction and second direction perpendicular to each other) rather than a single direction. This multi-dimensional arrangement allows the spring member to provide compression force while maintaining electrical conductivity through spatial distribution of contact points.
2Area of stationary object
If the contact member size is increased to provide larger contact area, then the electrical conductivity improves, but the device complexity and space requirements increase
Solution Approach 1:
The spring member is designed with flexible spring arms that can dynamically adjust their position and compression force based on the mating terminal's characteristics. This dynamic adaptation allows the terminal assembly to maintain optimal contact area without requiring a larger fixed-size contact member, thereby reducing device complexity.
Solution Approach 2:
The spring member allows for parameter changes in compression force and contact pressure through its elastic deformation. By varying the spring constant and arm configuration, the system can achieve larger effective contact area through increased pressure rather than increased physical size, avoiding the need for larger contact members.
3Stability of the object's composition
If the spring member material has inferior electrical conductivity, then the relaxation resistance improves, but the overall electrical performance deteriorates
Solution Approach 1:
The terminal assembly uses a composite material strategy where the spring member material (with high relaxation resistance) is combined with contact member materials (with high electrical conductivity). The shroud material also forms part of this composite system, creating a multi-material assembly that achieves both relaxation resistance and electrical conductivity through the combined properties of different materials working together.
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 design enhances the contact area and strength of the terminal assembly, maintaining effective electrical conductivity and protecting the contact arms from damage, while allowing for a wider and more robust connection.
Implementation Method 1
The spring member maintains the desired compression force without requiring that the size of the contact member be increased and allows the female terminal assembly to maintain a desired contact area with the male terminal, even when the temperature of the female terminal increases.
Data Source
AI summary
An electrical connector assembly includes a contact member and a spring member. The contact member has a base and contact arms that extend from the base in an arm direction on opposite sides of a terminal plane. The spring member is supported on the contact member and includes a spring base and spring arms that extend from the spring base in the arm direction. The spring arms are on opposite sides of the terminal plane and engage respective ones of the contact arms at respective spring contacts. The spring member also includes a shroud that is connected to the spring base and has an end shield that extends beyond the arms. The shroud includes side shields that are located on opposite sides of the contact arms and connect the end shield to the spring base. Shield arms also connect the end shield to the spring base.