High-Current Connector Embedding Stranded Wire in Molding
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Solution Overview
Problem
The existing high-current electrical connector production methods are time-consuming and costly, requiring separate manufacturing of stranded wires and connecting pieces followed by soldering or welding, which complicates the process and increases costs.
Innovation Solution
The stranded wire is embedded or incorporated into a connecting piece using a molding method such as casting or forging, eliminating the need for separate manufacturing and soldering/welding processes, and enhancing electrical transition resistance while allowing for a more compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate manufacturing of stranded wire and connecting piece followed by soldering or welding is used, then reliable electrical connection is achieved, but manufacturing time and cost increase
Solution Approach 1:
The patent combines the stranded wire and connecting piece into a single integrated component through embedding. The stranded wire is embedded within the connecting piece material, eliminating the need for separate manufacturing and joining processes (soldering or welding). This merging approach maintains reliable electrical connection while significantly reducing manufacturing time and complexity.
2Reliability
If separate manufacturing and soldering/welding process is used, then electrical connection is established, but manufacturing complexity and cost increase
Solution Approach 1:
The manufacturing process is simplified by merging multiple steps (separate manufacturing of stranded wire and connecting piece, preparation for soldering/welding, and joining) into a single embedding process. The stranded wire is directly embedded into the connecting piece material, eliminating the need for separate preparation and joining operations.
3Ease of manufacture
If traditional separate manufacturing approach is used, then components can be produced independently, but overall connector size increases
Solution Approach 1:
The patent applies the nesting principle by placing the stranded wire inside the connecting piece material. The stranded wire is embedded within the body of the connecting piece, creating a compact integrated structure. This nested arrangement reduces the overall connector size compared to separate components joined together.
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 approach simplifies the manufacturing process, reduces costs, and results in a high-current connector with improved electrical transition resistance and a smaller form factor.
Implementation Method 1
using a molding method such as casting or forging
Implementation Method 2
using a molding method such as casting or forging
Data Source
AI summary
A high-current electrical connector comprises a stranded wire and a connecting piece. The stranded wire has a longitudinal end section. The longitudinal end section of the stranded wire is incorporated in a material of the connecting piece.