Bus Bar Connector Layout for Narrower Power Plug Assemblies
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Solution Overview
Problem
Existing power connectors are widened by flat terminals, increasing their size and width, which is inefficient for mating with bus bars.
Innovation Solution
A connector design featuring longitudinally extending plate-shaped fixing and terminal portions with laterally extending connection portions, where the spacing between the fixing portions is greater than between the terminal portions, allowing for a more compact arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flat terminals are used to connect wires to bus bars, then electrical connection reliability is improved, but the width of the connector increases
Solution Approach 1:
The terminal structure transitions from a flat two-dimensional configuration to a three-dimensional configuration by adding a connection portion that extends in a direction substantially perpendicular to the plate-shaped fixing portion. This dimensional change allows the terminal to achieve reliable electrical connection without increasing the connector width in the conventional plane, effectively resolving the contradiction between connection reliability and compactness.
2Adaptability or versatility
If positive and negative terminals are arranged at both sides of the insulation housing in width direction, then electrical connection functionality is improved, but the overall size of the power connector increases
Solution Approach 1:
The terminal design extends the connection portion in a direction substantially perpendicular to the plate-shaped fixing portion, utilizing the third dimension (height/depth) rather than only the width direction. This allows both positive and negative terminals to be arranged with their connection portions extending outward, achieving full electrical connection functionality while maintaining a compact width profile and reducing overall connector size.
Data Source
AI summary
A connector includes a first terminal assembly having a longitudinally extending first plate-shaped fixing portion, a longitudinally extending first terminal portion, and a substantially laterally extending first connection portion to connect the first plate-shaped fixing portion and the first terminal portion. A second terminal assembly is arranged opposite to and spaced apart from the first terminal assembly and includes a longitudinally extending second plate-shaped fixing portion, a longitudinally extending second terminal portion, and a substantially laterally extending second connection portion to connect the second plate-shaped fixing portion and the second terminal portion. A spacing between the first plate-shaped fixing portion and the second plate-shaped fixing portion is greater than a spacing between the first terminal portion and the second terminal portion.