Composite Sealed Terminal Assembly for Low-Voltage High Current
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Solution Overview
Problem
Existing sealed terminals for automotive air conditioners, made of stainless steel, are unsuitable for low-voltage systems as they require large cross-sections and generate excessive heat due to high resistance when handling currents of 100-150A.
Innovation Solution
A sealed terminal assembly comprising conductive needles with a copper core and a steel sleeve, along with insulating members like ceramic rings and glass sintered pieces, which reduce electrical resistance and heat generation while maintaining good bonding and conductivity for low-voltage applications without significant volume increase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stainless steel terminal is used for low-voltage system, then the terminal can handle high current, but the cross section becomes large and heat generation increases
Solution Approach 1:
The terminal uses a composite structure with copper core and stainless steel sleeve. The copper core provides low electrical resistance for high current handling, while the stainless steel sleeve provides mechanical strength and sealing capability. This composite material approach allows the terminal to handle 100-150A current in low-voltage systems without requiring a large cross-section, as the copper core efficiently conducts electricity while the steel sleeve maintains structural integrity.
Solution Approach 2:
Different parts of the terminal have different material properties optimized for their specific functions. The inner core uses copper for optimal electrical conductivity, while the outer sleeve uses stainless steel for mechanical strength and environmental resistance. This local differentiation of material quality allows the terminal to achieve both low resistance and high strength without increasing overall volume.
2Reliability
If stainless steel terminal is used for low-voltage system, then the terminal can handle high current, but heat generation becomes large
Solution Approach 1:
The copper core in the composite terminal structure has significantly lower electrical resistance than stainless steel, reducing I²R heat generation when handling 100-150A currents. The stainless steel sleeve provides mechanical support without being the primary current conductor, thus minimizing overall heat generation while maintaining current handling capability.
3Reliability
If copper core with steel sleeve is used, then electrical conductivity improves, but device complexity increases
Solution Approach 1:
The copper core and stainless steel sleeve are merged into a single integrated terminal component through interference fit or welding. This combining of materials into one unified structure provides both electrical conductivity and mechanical strength without requiring separate assembly steps, thus minimizing the increase in device complexity while achieving superior electrical performance.
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 provides improved electrical conductivity and reduced heat generation, making it suitable for low-voltage situations without increasing the terminal's volume, effectively addressing the limitations of stainless steel terminals in low-voltage systems.
Implementation Method 1
the copper core has a much lower electrical resistance than the steel sleeve, has good electrical conductivity when large currents pass, and therefore reduces heat generation
Implementation Method 2
the copper core has a much lower electrical resistance than the steel sleeve, has good electrical conductivity when large currents pass, and therefore reduces heat generation
Implementation Method 3
the steel sleeve cladding the copper core retains good bonding ability with the glass sintered piece
Implementation Method 4
at least one insulating member, each of the at least one insulating member is located between the corresponding conductive needle and the body, and is used for connecting the conductive needle to the body in an insulating manner
Implementation Method 5
the insulating member includes a ceramic ring sleeved on the outside of the conductive needle
Data Source
Figure 1~2
Figure 3~5
AI summary
A sealed terminal assembly is disclosed asi including a body having at least one conductive needle mounting hole penetrating the body, at least one conductive needle mounted in the conductive needle mounting hole, and at least one insulating member located between the corresponding conductive needle and the body. The insulator connects the conductive needle to the body in an insulating manner. The conductive needle includes a copper core and a steel sleeve cladding the outer periphery of the copper core. The sealed terminal assembly has improved electrical conductivity and reduced heat generation and is especially suitable for low voltage situations.