Electric Connector With Sliding Conducting Elements
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Solution Overview
Problem
Conventional electric connectors are limited to a maximum current of about 500 A, which is insufficient for high power applications such as electric vehicles, and lack maintainability features.
Innovation Solution
A high power electric connector design featuring a connector body with a connector core and protruding cuboidal elements forming a rectangular U, incorporating slidably arranged conducting elements that can handle currents up to 3 kA and 1.5 kV, with enhanced maintainability through easy replacement of conducting elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional charging connectors are used, then the current handling capability is limited to about 500 A, but the design is simpler and more conventional
Solution Approach 1:
The connector is divided into modular components including a connector body, connector core, and multiple protruding cuboidal elements. Each cuboidal element contains conducting elements that can be independently replaced, allowing the high current capability (3 kA) to be achieved through modular segmentation rather than a monolithic complex structure.
Solution Approach 2:
The conducting elements are designed to be slidable within the cuboidal elements, transitioning between fixed operational positions and removable replacement positions. This dynamic design enables easy maintenance and replacement without requiring complex disassembly procedures.
2Ease of repair
If conventional charging connectors are used, then the manufacturing process is standard, but the maintainability is poor
Solution Approach 1:
The conducting elements are segmented as separate replaceable components within the cuboidal elements. This segmentation allows individual conducting elements to be replaced without replacing the entire connector, significantly improving maintainability while the modular design remains manufacturable using standard processes.
Solution Approach 2:
The conducting elements are extracted as independent replaceable components from the cuboidal elements. The sliding mechanism allows these elements to be easily removed and replaced, enabling quick maintenance and repair operations without complex manufacturing requirements.
3Ease of repair
If the conducting element is fixed rigidly, then the electrical contact is stable, but the replacement and maintenance are difficult
Solution Approach 1:
The conducting elements are designed with sliding capability within the cuboidal elements, allowing them to be easily removed for replacement while maintaining stable electrical contact during operation. The sliding mechanism provides a dynamic solution that switches between fixed (stable contact) and movable (replaceable) states.
Solution Approach 2:
The cuboidal elements act as intermediary structures that hold the conducting elements in a slidable manner. This intermediary design allows the conducting elements to maintain stable contact during use while enabling easy removal and replacement when needed.
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
Enables efficient high power transfer while improving maintainability by allowing easy substitution and repair of conducting elements, reducing lifetime costs and enhancing reliability for heavy vehicles and high-power devices.
Implementation Method 1
the conducting element and at least one notch of the notches are configured for conducting charging current
Implementation Method 2
The conducting elements may comprise or consist of highly conducting material, such as copper, others or a conducting alloy, possibly with a highly conducting coating material, such as gold or silver. The conducting elements may be elastic, at least partly, to reduce an electric transition resistance to the conducting structure by exerting a pressure on the conducting structure.
Data Source
AI summary
An electric connector includes a connector body having a connector core and two protruding cuboidal elements that, together, form a U shape. At least one conducting element is arranged at an inner side of the protruding cuboidal element. The conducting element protrudes, at least partly, from the inner side. The conducting element is arranged slidably between two notches, which are arranged in the cuboidal element. The conducting element and at least one notch of the two are configured for conducting charging current.