High Current Connector Resilient Conductor Vibration Stability
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Solution Overview
Problem
Conventional high current connectors fail to provide reliable and safe electrical connections, especially under mechanical stress like shaking or vibrations, due to inadequate contact point durability and shifting issues.
Innovation Solution
A high current connector system utilizing a resilient electrical conductor with a spiral design that securely fastens a conductive element through elastic stretching, ensuring stable contact and preventing abrasion by matching the shape of the insertion slot and conductive element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional connector uses screws for electrical connection, then the connection is secure and stable, but the connection establishment is slow and complex
Solution Approach 1:
The patent replaces the screw fastening mechanism with an elastic resilient body that uses elastic deformation to secure the conductive element. The resilient body deforms elastically when the conductive element is inserted and maintains continuous contact pressure without requiring threading or tightening operations, thus eliminating the mechanical complexity of screws while maintaining connection stability.
Solution Approach 2:
The resilient body is designed to be dynamically adaptable, automatically adjusting its elastic deformation to match the inserted conductive element. This dynamic response allows the connector to establish secure electrical contact rapidly through simple insertion, eliminating the static, multi-step screw fastening process while maintaining reliable connection under varying conditions.
2Volume of moving object
If a connector is designed with small size, then the device is compact, but the contact area and connection reliability are reduced
Solution Approach 1:
The resilient body concentrates its fastening function in a localized elastic deformation zone, allowing the connector to maintain small overall dimensions while providing sufficient contact pressure and area at the critical interface between the resilient body and conductive element. The elastic material distributes contact pressure locally to ensure reliable electrical connection without requiring a large connector structure.
Solution Approach 2:
The use of elastic resilient material combines mechanical compliance with electrical conductivity, creating a composite structure that provides both mechanical fastening and electrical connection functions within a compact form factor. The elastic material allows for adequate contact area and pressure within reduced spatial dimensions compared to rigid screw-based systems.
3Device complexity
If a connector uses rigid contact points, then the structure is simple, but the contact points are prone to abrasion and wear under vibration and shaking
Solution Approach 1:
The patent changes the mechanical parameter of the contact point from rigid to elastic, allowing the resilient body to deform and absorb mechanical stresses from vibration and shaking. This parameter change transforms the contact point from a brittle, wear-prone rigid structure to a compliant, self-adjusting elastic structure that maintains continuous contact under dynamic conditions while remaining relatively simple in design.
Solution Approach 2:
The elastic resilient body provides beforehand cushioning by absorbing and dissipating mechanical shocks and vibrations through elastic deformation before they can cause abrasion or damage to the contact points. This pre-cushioning effect protects the contact interface from harmful mechanical stresses while maintaining simple structural design without requiring additional damping components.
4Productivity
If a connector allows quick plug-in connection, then the connection establishment is fast, but the fastening force and contact reliability are insufficient
Solution Approach 1:
The resilient body performs self-service by automatically generating the necessary fastening force through its own elastic deformation when the conductive element is inserted. No external fastening action is required - the resilient body self-adjusts to provide adequate contact pressure and mechanical retention, achieving both quick connection establishment and sufficient fastening strength through its inherent elastic properties.
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 safe, reliable, and stable electrical connection capable of transmitting high currents while maintaining contact quality even under mechanical stress, with a large contact area and low tolerance for wear, preventing shifting and ensuring correct insertion angles.
Implementation Method 1
The resilient electrical conductor includes a resilient body, an insertion space formed inside the resilient body, and a plurality of gaps formed on the resilient body. The conductive element is fixed in the insertion slot by means of stretchable configuration of the gaps.
Data Source
AI summary
A high current connector and a socket connector of the high current connector are provided. The high current connector includes a first connector, a resilient electrical conductor and a second connector. The first connector includes an insertion slot. The resilient electrical conductor is received in the insertion slot and includes a resilient body, an insertion space formed inside the resilient body, and gaps arranged annularly on the resilient body. The second connector includes a conductive element inserted in the insertion space, the conductive element is electrically connected to the first connector through the resilient electrical conductor and is fixed in the insertion slot by means of stretchable configuration of the gaps. Accordingly, the resilient electrical conductor tightly fixes the conductive element to achieve reliable and safe connection and also improve contact quality.