Dual-Layer High-Voltage Terminal Body for Stable Wire Welding
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Solution Overview
Problem
The existing connector terminal bodies for high-voltage connections suffer from poor structural stability and conductivity due to the single-layer arrangement of contact plates and relative movement during ultrasonic welding, leading to inefficient electrical connections.
Innovation Solution
A terminal body design featuring a dual-layer arrangement with a first and second insertion plate forming an insertion slot and a wiring portion comprising a first and second wiring plate connected through a connection bridge, along with an alignment structure including a through hole and boss, which allows for simultaneous electrical connection to the core wire, enhancing conductivity and structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-layer insertion plate is used, then the structure is simple, but the current-carrying performance is poor due to long conduction path and small conduction section
Solution Approach 1:
The patent transitions from a single-layer structure to a dual-layer structure by adding the second insertion plate parallel to the first insertion plate. This dimensional change creates multiple conduction paths simultaneously, reducing the effective conduction path length and increasing the total conduction cross-section, thereby improving current-carrying performance while maintaining reasonable structural complexity
Solution Approach 2:
The single insertion plate is segmented into two separate insertion plates (first and second insertion plates) that are electrically connected. This segmentation allows each plate to provide independent conduction paths, and when combined, they offer redundant and parallel current flow routes, enhancing overall current-carrying capacity
2Strength
If ultrasonic welding is used to connect wiring plates to wire cores, then the connection is strong, but relative movement occurs between wiring plates during welding, causing poor electrical connection
Solution Approach 1:
The first and second wiring plates are merged into a unified structure where they are electrically connected to each other and to the wire core simultaneously. This merging ensures that during ultrasonic welding, both plates maintain fixed relative positions, preventing relative movement and ensuring consistent electrical connection precision while maintaining strong connection strength
Solution Approach 2:
The wire core acts as an intermediary element that connects both the first and second wiring plates simultaneously. This intermediary configuration stabilizes the relative positions of both wiring plates during the ultrasonic welding process, preventing relative movement between them while ensuring strong electrical connections to both plates
Data Source
AI summary
The present application provides a terminal body for high-voltage connection, a cable assembly and a connector. The terminal body has an insertion portion and a wiring portion, the insertion portion includes a first insertion plate and a second insertion plate, wherein a gap is formed between the first insertion plate and the second insertion plate, and the first insertion plate and the second insertion plate are enclosed together to form a insertion slot configured for inserting a mating terminal; the wiring portion includes a first wiring plate, a second wiring plate and an alignment structure, the first wiring plate is electrically connected with the first insertion plate, and the second wiring plate is electrically connected with the second insertion plate, the first inner side surface of the first wiring plate is arranged facing the second inner side surface of the second wiring plate, the alignment structure includes a through hole and a boss, the through hole is provided on the first wiring plate, and the boss is provided on the second inner side surface, the boss is accommodated in the through hole, and is configured to be electrically connected to a core of a wire together with the first outer side surface. The core of the wire can be electrically connected to both the first wiring plate and the second wiring plate at the same time, which improves the conductivity and current-carrying performance of the wiring portion.