Electrical Connection Device With Embedded Insulator Cutout
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Solution Overview
Problem
The miniaturization of Field-Effect Transistors (FETs) leads to a reduced separation distance between terminals, making it difficult to prevent contact between bus bars connected to the source and gate terminals, hindering the reduction of electrical junction box size.
Innovation Solution
An electrical connection device with a first conductive plate having a cutout and an embedded insulator, where a conductive path on the insulator's surface is connected to the control terminal, preventing contact between the conductive plates and the path, allowing for the use of closely arranged small switching elements, reducing the device's size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a small FET is used to reduce the size of the electrical junction box, then the device size is reduced, but the separation distance between the source terminal and gate terminal becomes too short, making it difficult to prevent contact between bus bars
Solution Approach 1:
The patent moves the gate terminal connection from a planar arrangement on the circuit board to a three-dimensional configuration using a via hole that penetrates through the insulator. This vertical dimension allows the gate terminal to be positioned below the insulator surface while the source terminal remains on the surface, maintaining adequate separation distance even when bus bars are placed close together on the same plane.
Solution Approach 2:
The patent introduces an insulator as an intermediary component between the source terminal and gate terminal connections. The insulator with embedded via hole acts as a mediator that electrically connects the gate terminal while providing physical insulation and maintaining spatial separation from the source terminal connection, preventing bus bar contact.
2Length of moving object
If the separation distance between source terminal and gate terminal is reduced, then the device can be miniaturized, but it becomes difficult to ensure that bus bars connected to these terminals do not contact each other
Solution Approach 1:
The patent utilizes the vertical dimension by creating a via hole through the insulator to connect the gate terminal. This allows the gate terminal to be positioned in a different vertical plane from the source terminal, enabling bus bars to be placed close together horizontally without risk of contact, thus simplifying manufacturing.
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 the use of small switching elements with closely arranged terminals, effectively reducing the size of the electrical connection device while maintaining insulation and preventing short circuits.
Implementation Method 1
an insulator embedded in the cutout, and a conductive path that is provided on the surface of the insulator and that does not contact the first conductive plate
Data Source
AI summary
An electrical connection device includes a first conductive plate provided with a cutout in a circumferential edge portion of the first conductive plate and a second conductive plate adjacent to the first conductive plate without contacting the first conductive plate. A switching element includes a first terminal connected to the first conductive plate, a second terminal connected to the second conductive plate, and a control terminal, and that is turned on or off according to a voltage of the control terminal, wherein the electrical connection device further includes an insulator embedded in the cutout. A conductive path is provided on the surface of the insulator and that does not contact the first conductive plate, and to which the control terminal is connected.