Large-Current Cable Connector Layout for Fast Assembly and Cooling
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Solution Overview
Problem
Existing connectors are complex to manufacture, cumbersome to assemble, and suffer from high current impedance, leading to overheating and restricted space occupancy, with poor heat dissipation due to bundled wiring.
Innovation Solution
A large current cable connector design featuring insulating body, positive and negative conductors with staggered wiring-seats on opposite sides, allowing easy assembly and reduced space occupation, improving heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the positive cable and negative cable are welded on different adapter boards and connected through overlap terminals, then the electrical connection is achieved, but the structure becomes complicated and assembly becomes cumbersome
Solution Approach 1:
The patent merges the positive and negative cable connections into a single integrated connector body. The connector includes a housing with a receiving space that accommodates both positive and negative cables, eliminating the need for separate adapter boards and overlap terminals. This integration simplifies the overall structure while maintaining reliable electrical connection through direct contact between cable terminals and connector contacts.
2Power
If multiple positive cables and negative cables are assembled simultaneously to increase current, then the current capacity increases, but the assembly time increases and heat dissipation becomes poor
Solution Approach 1:
The connector is designed with segmented contact structures that can independently receive and connect multiple positive and negative cables. The housing contains separate receiving spaces and contact elements for each cable connection, allowing parallel assembly of multiple cables without interfering with each other. This segmentation enables simultaneous connection of multiple cables to achieve high current capacity while maintaining efficient assembly throughput.
Solution Approach 2:
The patent arranges cable connections in three-dimensional space within the housing, utilizing vertical and lateral dimensions to position multiple cable terminals and contacts. This spatial arrangement allows multiple cables to be connected simultaneously without overlapping or interfering with each other, reducing assembly time while maintaining high current capacity through parallel connection paths.
3Reliability
If the positive cable and negative cable extend away from the overlap terminals, then the electrical connection is formed, but the occupied space increases and heat dissipation is hindered
Solution Approach 1:
The connector design nests the cable terminals and contacts within a compact housing structure. The positive and negative cable terminals are positioned adjacent to each other within the receiving space, with contacts that engage directly without requiring extended cable runs. This nested arrangement minimizes the occupied volume while ensuring reliable electrical connection through direct terminal-to-contact engagement.
Data Source
AI summary
A large current cable connector having an insulating body, a positive conductor, and a negative conductor is provided. The positive conductor includes a first buried section and a first exposed section and has a plurality of positive wiring-seats. The negative conductor includes a second buried section and a second exposed section and has a plurality of negative wiring-seats. The first buried section and the second buried section are arranged in the insulating body. The first exposed section and the second exposed section are exposed outside the insulating body. Some of the positive wiring-seats are located on a side of the positive conductor, others are located on another side of the positive conductor. Some of the negative wiring-seats are located on a side of the negative conductor, others are located on another side of the negative conductor. The large current cable connector is therefore conveniently manufacturing and assembling cables quickly.