High-Current Connector With Conductive Spacer Projections
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Solution Overview
Problem
Connectors used with high-current terminals often suffer from insufficient electric conductivity and lack of current adjustment capability, which limits their effectiveness in applications such as network energy equipment and industrial power distribution.
Innovation Solution
A connector design featuring a main body with a pluggable portion and a conductive spacer with multiple outer and inner projections that increase electrical contact points and allow for current adjustment by adjusting the spring force generated by these projections, enhancing both conductivity and current control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional connector structure is used, then the structure is simple, but the electric conductivity is insufficient
Solution Approach 1:
The connector introduces a conductive spacer with multiple outer projections and inner projections that divide the contact interface into multiple discrete electrical contact points. This segmentation increases the number of parallel conduction paths, thereby improving overall electric conductivity while maintaining a relatively simple overall structure.
Solution Approach 2:
The invention transitions from a single-plane contact interface to a multi-dimensional contact structure by adding projections that extend in multiple directions. The outer projections engage with the pluggable portion while inner projections contact the high-current terminal, creating contact points distributed across different spatial dimensions and improving conductivity.
2Adaptability or versatility
If a conventional connector structure is used, then the manufacturing is simple, but the current adjustment capability is lacking
Solution Approach 1:
The conductive spacer incorporates bent projections that generate spring force, creating a dynamic contact system. The spring force allows the projections to maintain optimal contact pressure and enables current adjustment by modifying the number or configuration of projections, providing adaptability without complex adjustment mechanisms.
Solution Approach 2:
The invention enables current adjustment by changing the number of outer projections and inner projections. By varying this parameter during manufacturing, different current capacities can be achieved with the same basic structure, providing versatility while maintaining manufacturing simplicity through a single design family.
3Reliability
If the number of projections is increased to improve conductivity, then the electric conductivity improves, but the device complexity increases
Solution Approach 1:
The conductive spacer merges multiple functions into a single component: it provides structural support, creates multiple electrical contact points through integrated outer and inner projections, and generates spring force through its bent configuration. This consolidation improves conductivity without proportionally increasing overall device complexity.
Solution Approach 2:
The conductive spacer serves multiple purposes simultaneously: it acts as an electrical conductor, a mechanical connector, and a spring element. The same projections that increase contact points also provide holding force through spring action, reducing the need for separate components and mitigating complexity increases.
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 design significantly improves electric conductivity and current adjustment capabilities, providing a robust and adjustable connection for high-current terminals, addressing the limitations of existing connectors.
Implementation Method 1
the shapes of the outer projection and the inner projection generate spring force, the holding force of the pluggable portion on the high-current terminal can be adjusted by adjusting the spring force of the outer bent projections and the inner bent projections
Implementation Method 2
The conductive spacer is disposed between the pluggable portion and the high-current terminal; the conductive spacer has a plurality of outer projections pressed against the pluggable portion and a plurality of inner projections pressed against the high-current terminal
Data Source
AI summary
A connector (10) used with a high-current terminal (100) includes a main body (1) and a conductive spacer (2). The main body (1) has a connecting portion (11) disposed at one end thereof and a pluggable portion (12) disposed at the other end thereof. The high-current terminal (100) is plugged into the pluggable portion (12). The conductive spacer (2) is disposed between the pluggable portion (12) and the high-current terminal (100). The conductive spacer (2) has a plurality of outer projections (21) pressed against the pluggable portion (12) and a plurality of inner projections (22) pressed against the high-current terminal (100). Thus, the number of electrical contact points is increased by means of the outer projections (21) and the inner projections (22) disposed between the pluggable portion (12) and the high-current terminal (100) such that the connector (10) has excellent electric conductivity and current adjustment capability.