Flexible Electrical Connector for Relative Displacement Buffering
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Solution Overview
Problem
Existing electrical connection methods in electric vehicles, such as those using conductive copper bars and flexible wires, often result in rigid connections with poor buffering performance and high failure rates due to limited adaptability to relative displacement changes.
Innovation Solution
A flexible electrical connection device featuring a hollow connecting cavity made of flexible conductive materials, such as a spherical-like or grid-like structure, with conductive plugs electrically coupled using crimping or welding, and equipped with annular springs for enhanced conductivity and adaptability, allowing for elongation, compression, and radial twisting to accommodate changes in displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If rigid connection methods (conductive copper bars and flexible wires) are used, then structural stability is improved, but adaptability to relative displacement deteriorates
Solution Approach 1:
The patent applies the dynamics principle by transforming the rigid connection structure into a flexible, dynamic one. The connecting cavity is designed with flexible conductive materials that can dynamically adapt to relative displacement between connectors while maintaining electrical connection. This allows the structure to change its configuration in response to movement, resolving the contradiction between structural stability and adaptability.
Solution Approach 2:
The patent directly applies this principle by using flexible conductive materials to form the connecting cavity. These flexible materials can deform and adapt to relative displacement between connectors, providing both the needed adaptability and maintaining structural integrity through their elastic properties, thus resolving the contradiction between rigidity and flexibility.
2Ease of manufacture
If rigid connection methods are used, then manufacturing simplicity is improved, but connection reliability deteriorates
Solution Approach 1:
The flexible conductive materials forming the connecting cavity provide inherent buffering capability that protects against connection failure due to displacement. This flexible structure absorbs mechanical stress and prevents rigid fracture, thereby improving connection reliability while maintaining relatively simple manufacturing processes.
Solution Approach 2:
The flexible conductive materials in the connecting cavity provide beforehand cushioning by absorbing and distributing mechanical stress before it can cause connection failure. This pre-cushioning effect protects the electrical connection from harsh conditions and displacement, improving reliability without significantly complicating manufacturing.
3Adaptability or versatility
If flexible conductive materials are used to create a connecting cavity, then adaptability to displacement changes is improved, but manufacturing complexity increases
Solution Approach 1:
The patent uses flexible conductive materials to form the connecting cavity, which can be manufactured as an integrated component. This approach provides high adaptability to displacement changes while keeping the manufacturing process relatively simple by using flexible materials that can be formed into the required cavity shape in one piece or with minimal assembly steps.
4Reliability
If conductive plugs with springs are used, then electrical conductivity is improved, but device complexity increases
Solution Approach 1:
The patent merges the conductive plug and spring into an integrated assembly where the spring serves dual purposes: providing mechanical buffering and ensuring electrical contact. This combination improves electrical conductivity through the spring's constant pressure contact while minimizing device complexity by integrating multiple functions into a single component 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
The solution provides a reliable and adaptive electrical connection that prevents performance degradation under varying conditions, enhancing conductivity and suitability for severe shaking environments without the need for bolts, ensuring reliable electrical connections in small spaces.
Implementation Method 1
a spring is disposed between ends of two conductive plugs extending into the connecting cavity
Implementation Method 2
a connector having a hollow connecting cavity formed by a plurality of flexible conductive materials, and each of two opposite sides of the connecting cavity being connected to a conductive plug electrically coupled with the connecting cavity
Data Source
AI summary
Provided is an electrical connection device (1) including a connector (2) having a hollow connecting cavity (21), each of two opposite sides of the connecting cavity is connected to a conductive plug (22) electrically coupled with the connecting cavity (21). The connecting cavity (21) is form by a plurality of flexible conductive materials. When in use, the grid-like connecting cavity (21) made of the flexible conductive materials can be elongated, compressed, or radially twisted, and is adaptive to changes in relative displacement at various angles at various angles in the axial direction or radial direction between different electrical connecting bases, thereby preventing degradation of performance of electrical connection due to the changes in relative displacement.