Angled Power Transfer Mechanism with Segmented Copper-Aluminum Terminal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power transmission systems require large copper terminals for high-current connections, leading to bulkiness, material waste, and increased costs due to non-axial or angled connections between cables and terminals.
Innovation Solution
A transfer mechanism for power transmission with a power transmission portion and a transfer portion, featuring a bent zone allowing angled connections and reduced copper usage, utilizing methods like welding, screwing, and crimping for efficient electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If copper terminals with large cross-sectional area are used for high-current connections, then the power transmission capability is improved, but the device becomes bulky and heavy
Solution Approach 1:
The terminal is divided into multiple segments: a copper connection end for high-current power transmission, an aluminum transfer portion for structural flexibility and weight reduction, and a cable connection end. This segmentation allows each part to be optimized for its specific function, reducing overall terminal weight while maintaining power transmission capability.
Solution Approach 2:
The terminal uses composite material construction with copper and aluminum sections joined together. The copper portion provides excellent electrical conductivity for high-current connections, while the aluminum portion reduces weight and allows for flexible angular connections. This composite structure resolves the contradiction between power transmission capability and weight.
2Adaptability or versatility
If copper terminals are used for angled or non-axial connections, then the connection flexibility is improved, but copper material consumption increases and cost rises
Solution Approach 1:
The terminal is segmented into copper and aluminum portions, where the aluminum transfer portion specifically handles the angled connection function. This allows the copper portion to be minimized to only what is necessary for electrical connection, reducing copper material consumption while maintaining connection flexibility through the aluminum section.
Solution Approach 2:
Different materials are applied to different parts of the terminal based on local requirements: copper is used where electrical conductivity is critical (connection end), while aluminum is used where structural flexibility and weight reduction are needed (transfer portion). This local quality differentiation reduces overall copper consumption while maintaining connection adaptability.
3Adaptability or versatility
If the cable connection position is far from the terminal position, then the design flexibility is improved, but copper material consumption increases due to extended terminal length
Solution Approach 1:
The terminal is segmented into a compact copper connection end and an aluminum transfer portion that can extend to reach distant cable positions. This segmentation allows the copper material to be concentrated at the connection point where it is most needed, while the aluminum portion provides the extended reach without significantly increasing copper consumption.
Solution Approach 2:
The composite copper-aluminum structure allows the terminal to achieve extended reach through the aluminum portion while maintaining electrical efficiency with minimal copper. The aluminum transfer portion acts as a lightweight, low-cost extension that does not require the full conductivity of copper, thus reducing overall copper material consumption while maintaining cable positioning flexibility.
Data Source
Figure 1~2
Figure 3~5
Figure 6~8
AI summary
Provided by the present disclosure are a transfer mechanism for power transmission, charging socket, and motor vehicle. The transfer mechanism for power transmission includes a power transmission portion, a transfer portion and a cable, in which the power transmission portion includes a plug-in end and a connection end which are connected in sequence; the cable includes an internal conductor and an insulation layer wrapping the conductor; the transfer portion includes a first end, a bent portion and a second end which are connected in sequence; the first end is electrically connected to the connection end, the second end is electrically connected to the conductor on one end of the cable, and the bent portion comprises at least one bent zone. By using the transfer mechanism for power transmission of the present disclosure, a non-coaxial or angled connection can be realized between a terminal and the cable, and the copper material used by the terminal can be saved to reduce the cost of the terminal.