Circuit Breaker Press-Fit Socket Assembly for Reliable Terminal Connection
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Solution Overview
Problem
The existing methods for assembling circuit breakers in aircraft electrical systems, such as brazing or welding sockets to terminals, are costly and cumbersome, requiring multiple processes.
Innovation Solution
A circuit breaker design utilizing press fit connectors and sockets, which eliminates the need for brazing, soldering, or welding by using interference fits to establish electrical connections between terminals and sockets, minimizing the overall height and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brazing or welding is used to connect sockets to terminals, then reliable electrical connection is achieved, but assembly complexity and cost increase due to multiple processes
Solution Approach 1:
The patent replaces thermal joining processes (brazing/welding) with a mechanical press-fit system. The socket includes an outer diameter that is press-fit into the terminal, creating a mechanical interference fit that provides both mechanical support and electrical connection without requiring thermal processes or additional joining materials.
2Reliability
If brazing or welding is used to connect sockets to terminals, then reliable electrical connection is achieved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive thermal joining processes with a simpler mechanical press-fit operation. This eliminates the need for brazing materials, welding equipment, and associated quality control processes, significantly reducing manufacturing cost while maintaining connection reliability through the interference fit mechanism.
Solution Approach 2:
The press-fit socket design allows the socket itself to provide both the electrical connection and the mechanical retention through its interference fit with the terminal. The socket's outer diameter is designed to be slightly larger than the terminal's inner diameter, creating a self-retaining connection that does not require additional fasteners or joining processes.
3Reliability
If traditional joining methods are used, then electrical integrity is maintained, but assembly time and productivity decrease
Solution Approach 1:
The patent replaces multi-step thermal joining processes with a single mechanical press-fit operation. The socket is simply pressed into the terminal, creating both mechanical and electrical connection in one action, dramatically reducing assembly time and increasing productivity compared to brazing or welding processes that require multiple steps and longer cycle times.
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
This solution reduces assembly complexity and cost by providing a reliable, interference fit-based connection method that maintains electrical integrity without the need for traditional joining techniques, enhancing the efficiency and reliability of circuit breaker assembly.
Implementation Method 1
A circuit breaker design utilizing press fit connectors and sockets, which eliminates the need for brazing, soldering, or welding by using interference fits to establish electrical connections between terminals and sockets
Data Source
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AI summary
A circuit breaker includes a housing 102, separable contacts 104, a trip mechanism 112, a first terminal 114, a second terminal (116), a first press fit connector 118, a second press fit connector (118a), a first socket 122, and a second socket (122a). The first terminal is electrically connected with a first contact of the separable contacts and includes a first base section 160 disposed outwardly from the housing. The second terminal is electrically connected with a second contact and includes a second base section (170) disposed outwardly from the housing. The first press fit connector is attached to the first base section via a first press fit. The second press fit connector is attached to the second base section via a second press fit. The first socket is attached to the first press fit connector. The second socket is attached to the second press fit connector.