Twist-lock electrical connector assembly for high current
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Solution Overview
Problem
Existing electrical connectors, such as post and cup sockets, are not suitable for high-power applications like rear window defrosters due to their limited current carrying capability.
Innovation Solution
A low-profile electrical connector assembly featuring a male terminal with offset contact arms and a female terminal with receptacle features, allowing for a secure high-current connection by twisting the male terminal around a pivot point on the female terminal, providing tactile feedback and preventing further rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a cup shaped female socket with resilient contact tabs is used, then the connector is suitable for low power applications, but it cannot handle high power applications such as rear window defrosters
Solution Approach 1:
The connector employs a dynamic twisting motion during engagement, where the male terminal rotates around the pivot feature of the female terminal. This dynamic engagement process allows the contact arms to progressively engage with the receptacle features, ensuring secure electrical contact while accommodating the higher current requirements through the robust rotational locking mechanism
Solution Approach 2:
The male terminal is divided into multiple segmented contact arms that can independently engage with the receptacle features of the female terminal. This segmentation allows for distributed current flow across multiple contact points, increasing the overall current carrying capability while maintaining adaptability to high power applications
2Reliability
If a male circular post with cup shaped female socket is used, then the structure is simple, but it lacks the secure engagement and tactile feedback needed for high power applications
Solution Approach 1:
The connector incorporates tactile feedback through the twisting engagement mechanism. As the male terminal rotates around the pivot feature during connection, the user can physically feel the engagement progress and the secure locking position, providing immediate feedback that the connection is properly established. This enhances reliability without requiring complex additional components
Solution Approach 2:
The pivot feature is designed with a spherical or curved geometry that allows the male terminal to rotate smoothly during engagement. This curved surface enables the twisting motion to naturally guide the contact arms into proper alignment with the receptacle features, ensuring secure engagement while maintaining a relatively simple overall structure
Data Source
AI summary
An electrical connector assembly includes a male terminal having a first pivot feature and a plurality of contact arms extending from the first pivot feature. The assembly further includes a female terminal having a base plate defining a second pivot feature and a plurality of receptacle features configured to receive free ends of the plurality of contact arms as the first pivot feature engages the second pivot feature and the plurality of contact arms is rotated around the first and second pivot features.