Annular Electrical Connector for Controlled Current Distribution
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Solution Overview
Problem
High-power electrical connectors face challenges in reducing current per contact element without increasing space requirements or plug-in and sliding forces, as existing solutions often require additional contact elements, leading to thermal stress and potential failures.
Innovation Solution
An electrical connector design featuring a connecting element with a receiving hole and circumferentially extending grooves, where the current is distributed via contact elements and a control segment with varying electrical resistance, allowing controlled current distribution without increasing space or forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional contact elements are added in parallel to reduce current intensity per contact element, then current distribution is improved, but space requirements and plug-in and sliding forces increase
Solution Approach 1:
The single contact element is segmented into multiple contact zones along its length, allowing current to be distributed through different sections of the same contact element rather than requiring multiple separate elements. This is achieved by creating control segments with different electrical resistances that guide current flow through specific pathes.
Solution Approach 2:
Different sections of the contact element are given different electrical resistance properties to control current distribution locally. The control segments have higher electrical resistance than the side segments, creating preferential current paths that distribute current effectively without adding more contact elements.
2Reliability
If additional contact elements are added in parallel to reduce current intensity per contact element, then current distribution is improved, but plug-in and sliding forces increase
Solution Approach 1:
The contact element is divided into functional segments (control segments and side segments) with different electrical resistance characteristics. This segmentation allows current to be distributed through multiple pathes within the same contact element, achieving reliable current distribution without the mechanical force penalties of multiple separate elements.
Solution Approach 2:
By assigning different electrical resistance values to different local regions of the contact element, the invention creates controlled current distribution patterns that reduce thermal stress without requiring additional contact elements that would increase plug-in and sliding forces.
3Temperature
If current per contact element is reduced without additional contact elements, then thermal stress is reduced, but current distribution control becomes difficult
Solution Approach 1:
The contact element incorporates control segments with specifically engineered different electrical resistance values to actively control current distribution. This local variation in electrical properties allows precise control of current paths, reducing thermal stress on critical sections while maintaining overall current flow.
Solution Approach 2:
The invention changes the electrical resistance parameter of different segments of the contact element to control current distribution. By adjusting the resistance of control segments relative to side segments, the current flow is directed through preferred pathes, managing thermal stress without increasing device complexity.
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 solution effectively reduces current per contact element, preventing thermal overload and maintaining low plug-in and sliding forces, while maintaining a simple and cost-effective design.
Implementation Method 1
the control segment has an electrical resistance different from the electrical resistance of the side segment
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Electrical connector (44) comprising a connecting element (48) having a receiving hole (50) and being designed for mechanical and electrical connection to an electrical conductor (24), the receiving hole (50) having a plurality of grooves (52) extending circumferentially about an interior wall (54) of the receiving hole (50) and in communication with the receiving hole (50), and a plurality of contact elements (64), each contact element being housed in one of the plurality of grooves to ensure electrical contact with the electrical conductor (24) inserted in the connecting element (48). The connecting element (48) has a control segment (74a) extending longitudinally between two consecutive grooves (52) having an electrical resistance different from the electrical resistance of the side segments adjacent to the control segment (74a). The control segment (74a) can have a recess (70a) or be made of a material having a higher electrical resistance than the side segments.