Electrical Connector Back Pin Assembly After Box Closure
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Solution Overview
Problem
Existing electrical power equipment assembly methods require the mechanical interface of connectors to be chosen before closing the power equipment box, limiting flexibility in connectorization.
Innovation Solution
An electrical connector design featuring a back pin extremity that allows assembly after the box is closed, with a power contact and complementary connector that can be electrically connected through a coupling axis passing through a through hole in the box wall, enabling flexible connectorization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the connector is permanently fixed on the power circuit before closing the box, then the mechanical interface can be securely established, but the flexibility in connectorization is limited
Solution Approach 1:
The electrical connector is divided into two separate parts: a first electrical connector permanently fixed to the power circuit inside the box, and a second electrical connector (complementary connector) that is assembled after box closure. This segmentation allows independent assembly of each connector part, enabling flexible connectorization without requiring pre-planning of mechanical interfaces before box closure.
Solution Approach 2:
The first electrical connector is preliminarily prepared by being permanently fixed to the power circuit inside the box before closure, with its contact elements positioned to extend through or near the wall. This preliminary action enables the second connector to be easily assembled afterward by simply mating with the pre-positioned first connector, resolving the contradiction between flexibility and complexity.
2Adaptability or versatility
If the connector is assembled after the box is closed, then the flexibility in design is improved, but the mechanical interface selection must be done differently
Solution Approach 1:
By segmenting the connector into two separate connectors that are assembled at different stages, the design achieves flexibility while maintaining manufacturing ease. The first connector is manufactured and fixed inside the box, while the second connector is manufactured separately and assembled afterward by simple mating, avoiding complex post-assembly operations.
Solution Approach 2:
The wall of the box serves as an intermediary structure that facilitates the connection between the two connectors. The first connector's contact elements extend through or near the wall, and the second connector mates with them from the outside, using the wall as a mediator to enable flexible post-assembly while maintaining ease of manufacture.
3Power
If the power contact has a large cross-section for high current, then the current carrying capacity is improved, but the space required inside the box increases
Solution Approach 1:
The electrical connection is extended into a third dimension by having contact elements extend through the wall of the box. This allows the power contacts to have large cross-sections for high current capacity while minimizing the space they occupy inside the box, as the connection path extends outward rather than requiring additional internal volume.
Data Source
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AI summary
Electrical connector (1) comprising at least one electrical power contact (9) having a cross-section larger than 8 mm2 and adapted to mate with a complementary connector. The at least one power contact (9) comprises a front end adapted to be electrically connected with a first complementary contact of said complementary connector. The at least one electrical power contact (9) comprises a back pin (11) having a back pin extremity (12) located at the opposite end of the power contact with respect to the front end and adapted to be electrically connected with a second complementary contact of a second connector.