Electrical Connection Sleeve with Frustoconical Channel for Thermal Isolation

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Solution Overview

Problem

The high thermal conductivity of copper-based electrical connection devices in automotive applications leads to significant heat transfer, resulting in costly, heat-resistant conductors and expensive soldering processes, necessitating a solution to reduce costs while maintaining effective electrical connectivity.

Innovation Solution

An electrical connection device with a sleeve inserted into a connection orifice, featuring a frustoconical internal channel with localized spacings to restrict heat transfer between the electrode and the conductor, allowing the use of less expensive, lower thermal conductivity materials like stainless steel, and alternative connection methods such as crimping or screwing instead of welding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If copper-based electrical connection devices are used, then electrical conductivity is improved, but heat transfer to the conductor increases

Engineering Contradiction:

Improveelectrical conductivityVSAvoidheat transfer

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The connection device is divided into two distinct parts: a copper-based connection lug for electrical connection and a stainless steel sleeve for thermal isolation. This segmentation allows each material to perform its optimal function - copper for conductivity and stainless steel for heat resistance - thereby resolving the contradiction between electrical conductivity and heat transfer.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection device uses a composite structure combining copper and stainless steel materials. The copper connection lug provides excellent electrical conductivity while the stainless steel sleeve provides thermal isolation. This composite approach allows the device to simultaneously achieve high electrical conductivity and low heat transfer to the conductor.

Inventive Principle:

Principle #40Composite materials

2Temperature

If heat-resistant conductors are used, then temperature resistance is improved, but cost increases

Engineering Contradiction:

Improvetemperature resistanceVSAvoidcost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The stainless steel sleeve acts as an intermediary element between the hot electrode and the electrical conductor. It provides thermal isolation, protecting the conductor from high temperatures. This allows the use of standard, lower-cost conductors rather than expensive heat-resistant conductors, thereby resolving the contradiction between temperature resistance and cost.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If welding is used for connection, then electrical connectivity is improved, but manufacturing cost increases

Engineering Contradiction:

Improveelectrical connectivityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention replaces the welding process with a mechanical press-fit connection. The stainless steel sleeve is simply pressed into the connection lug, creating a reliable electrical and mechanical connection without requiring welding. This substitution eliminates the costly and complex welding process while maintaining good electrical connectivity, resolving the contradiction between connectivity and manufacturing cost.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 configuration reduces heat transfer to the electrical conductor, enabling the use of less expensive, less heat-resistant materials and simplifying the connection process, thereby lowering costs without compromising electrical conductivity or durability.

Implementation Method 1

the section of the channel normal to the longitudinal axis evolving along the longitudinal axis between the first opening and the second opening... restrict the contact between the electrode and the sleeve... which limits the exchange of heat between the electrode and the sleeve

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

the electrical conductivity of stainless steel is sufficient to ensure a good electrical connection between the electrode and the core of the electrical conductor

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentEP4037107A1Electrical connection device with socket

Publication Date: 2022.08.03 VM IND

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AI summary

The invention relates to an electrical connection device (10) comprising a connection member (20) having: - a first branch forming a connecting lug (22) provided with a through-hole for connection, and - a second branch, called the connecting branch (26), intended to be connected to the core of a conductor. The electrical connection device (10) further comprises a socket (36) inserted into the connection hole, the socket (36) defining an internal channel extending along a longitudinal axis connecting a first opening to a second opening, the cross-section of the channel perpendicular to the longitudinal axis varying along the longitudinal axis between the first and second openings.