Electrical Connector Conductive Medium Air Wall Elimination
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Solution Overview
Problem
The existing electrical connector structures experience increased resistance and temperature issues during large-current power transmission due to air walls formed between conductive bodies and core wires, which can be exacerbated by varying geometrical shapes and materials, leading to inefficiencies and structural weaknesses.
Innovation Solution
The electrical connector incorporates a conductive medium, such as copper powder, distributed between core wires and a groove in the wire-connection post, with a vent hole and riveting process to exhaust air and ensure full contact, creating a continuous conductive path across the connection section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cold work compression is applied to connect conductive bodies and core wires, then the connection is formed, but air walls are created between them causing increased resistance and temperature
Solution Approach 1:
A conductive medium is introduced as an intermediary substance between the conductive body and core wires. This conductive medium fills the gaps and eliminates air walls, providing continuous conductive paths while maintaining the mechanical connection structure.
Solution Approach 2:
The patent changes the physical state and distribution parameters of the conductive medium through controlled filling and compression processes. By adjusting the density and distribution of the conductive medium in the connection zone, optimal electrical conductivity is achieved while eliminating air pockets.
2Power
If the conductive body length is increased to accommodate larger currents, then current capacity improves, but resistance apparently increases
Solution Approach 1:
The patent optimizes the conductivity parameters by introducing conductive medium and controlling its distribution along the conductive body. This reduces the effective resistance per unit length, allowing longer conductive bodies to maintain low resistance while handling larger currents.
3Adaptability or versatility
If different geometrical shapes are used for the fixation structure, then adaptability improves, but conductivity varies
Solution Approach 1:
The conductive medium serves as a universal intermediary that adapts to different geometrical shapes of fixation structures. Regardless of the shape variations, the conductive medium fills the available space and ensures consistent electrical contact, maintaining conductivity reliability across different configurations.
4Reliability
If high conductivity materials are used for the conductive body, then conductivity improves, but manufacturing cost increases and structural strength decreases
Solution Approach 1:
The patent creates a composite connection structure where a standard conductive body is combined with a conductive medium. This composite approach achieves high overall conductivity without requiring expensive high-conductivity materials for the entire conductive body, reducing manufacturing costs while maintaining performance.
Solution Approach 2:
The conductive medium is applied locally at the connection zones where high conductivity is most critical. This localized approach provides high conductivity where needed without the expense of using high-conductivity materials throughout the entire conductive body structure.
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 effectively reduces resistance and prevents temperature increases during large-current transmission by eliminating air walls and ensuring a uniform conductive path, enhancing the structural integrity and conductivity of the connector.
Implementation Method 1
The conductive medium is distributed over a space between the core wires and a space between the core wires and the groove... allowing the conductive media (the conductive body and the cable member) to contact each other for conduction
Data Source
AI summary
An electrical connector and an electrical wire connection method for connecting electrical connectors with each other are provided. The electrical connector includes a conductive body, a conductive material, and a cable member. One of two ends of the conductive body includes an insertion portion, the other end of the conductive body includes a wire-connection post, and the wire-connection post has a groove. The conductive material is disposed in the groove. The cable member includes core wires inserted into the groove. The conductive medium is distributed over the space between the core wires and the groove.