High-Voltage Connector Flat-Plate Contact for Stable Low-Heat Mating
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Solution Overview
Problem
High-voltage connectors face challenges in connecting to mating terminals due to positional variations caused by device tolerances, requiring complex structures with stretchable conductors, which increase cost, size, and electrical resistance, and generate heat.
Innovation Solution
A high-voltage connector with a flat plate terminal body and an integrally inclined resilient contact portion, fixed to a connector housing with squeezable ribs, allowing for stable connection and reduced components, heat generation, and improved conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a stretchable conductor and displaceable female terminal structure are used to accommodate positional variations, then connection stability is improved, but device complexity, manufacturing cost, and electrical resistance increase
Solution Approach 1:
The patent changes the shape parameter of the terminal body from a conventional tubular form to a flat plate form. This parameter change eliminates the need for stretchable conductors and displaceable structures, achieving connection stability through the flat plate's inherent flexibility and direct contact capability, thereby reducing structural complexity while maintaining reliability
Solution Approach 2:
The patent extracts and eliminates the stretchable conductor component from the terminal structure. By using a flat plate terminal body that can directly accommodate positional variations through its own flexibility, the invention removes the separate stretchable conductor, reducing both device complexity and manufacturing cost while maintaining connection stability
2Reliability
If a tubular female terminal connected by crimping is used, then connection stability is achieved, but manufacturing complexity and electrical resistance increase
Solution Approach 1:
The patent merges the terminal body and contact elements into a single integrated flat plate structure. This eliminates the need for separate crimping operations to connect tubular terminals with conductors, simplifying the manufacturing process while maintaining connection stability through the integrated design
Solution Approach 2:
The flat plate terminal body can be manufactured as a simple, cost-effective component using stamping or bending processes rather than complex crimping operations. The simplified structure reduces manufacturing cost and complexity while achieving the required connection reliability
3Reliability
If conventional terminal structures are used, then connection functionality is achieved, but electrical resistance and heat generation increase
Solution Approach 1:
The patent changes the contact interface geometry from a point or line contact in tubular terminals to a broader surface contact in the flat plate terminal. This parameter change increases the contact area, reducing electrical resistance and consequently reducing heat generation while maintaining connection functionality
Solution Approach 2:
The flat plate terminal body can be constructed from materials with optimized electrical conductivity properties. By selecting appropriate conductive materials for the flat plate structure, the invention reduces electrical resistance and heat generation compared to conventional tubular terminal structures
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 achieves stable connection, reduced size, and lower electrical resistance while simplifying the structure and manufacturing process, thereby reducing costs and heat generation.
Implementation Method 1
a resilient contact portion integrally provided to the terminal body portion, the resilient contact portion being at least partially inclined to an overlapping side with the mating terminal
Data Source
AI summary
A high-voltage connector of a novel structure is disclosed which achieves an improvement in electrical conductivity, a reduced amount of heat generation and the like while realizing stable connection to a mating terminal by a simple structure having a small number of components. A high-voltage connector 10 is provided with a terminal fitting 16 including a terminal body portion 34 in the form of a flat plate to be overlapped on a mating terminal 76 in the form of a flat plate in a plate thickness direction, and a resilient contact portion 38 integrally provided to the terminal body portion 34 and inclined to an overlapping side with the mating terminal 76.