Electric Connection Skeleton Assembly for Low-Resistance HV Connectors
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Solution Overview
Problem
Existing electric energy transmission connecting devices for new energy automobiles face challenges such as high labor costs and time consumption due to manual mounting of high-voltage cables, excessive heat generation leading to connection failures, and high contact resistance between terminals and skeletons.
Innovation Solution
The electric energy transmission connecting device features an electric connection skeleton with a terminal structure that extends into a fixing cavity within the connector, reducing vibration-induced damage and contact resistance, while allowing for automatic assembly and improved thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual mounting is used for high-voltage cables, then connection reliability is improved, but labor cost and time cost increase
Solution Approach 1:
The patent integrates the terminal structure directly into the electric connection skeleton, eliminating the need for separate manual cable mounting operations. The terminal structure serves both as the connection interface and the mounting feature, combining multiple functions into a single integrated component that enables automated assembly while maintaining connection reliability.
Solution Approach 2:
The terminal structure is designed to perform multiple functions: it provides electrical connection, structural support, and vibration resistance. By making the terminal structure multi-functional, the patent eliminates the need for separate manual operations while maintaining the reliability that would otherwise require careful manual assembly.
2Power
If high-voltage cables transmit large current, then power transmission capability is improved, but heat generation increases causing connection failures
Solution Approach 1:
The patent divides the connection system into distinct functional zones: the terminal structure, the electric connection skeleton, and the connector body. This segmentation allows for optimized thermal management at each interface, with specific focus on reducing contact resistance at the terminal-skeleton interface to minimize heat generation during high-power operation.
Solution Approach 2:
The patent applies different material properties and structural characteristics to different parts of the connection system. The terminal structure uses materials and geometries optimized for low contact resistance and heat dissipation, while the connector body provides overall structural support. This local optimization ensures efficient heat management at critical interfaces during high-power transmission.
3Reliability
If copper terminal is used, then electric conductivity is improved, but cost increases
Solution Approach 1:
The patent employs composite material structures in the terminal and skeleton design, combining materials with different properties to achieve both high conductivity and cost-effectiveness. The terminal structure and electric connection skeleton are designed to work together as a composite system that maintains excellent electrical performance while using materials optimized for both performance and cost.
4Reliability
If connection terminal is connected to electric connection skeleton, then electrical connection is achieved, but contact resistance increases causing heating
Solution Approach 1:
The patent merges the terminal structure with the electric connection skeleton to create an integrated connection system. This integration eliminates separate connection interfaces that would introduce contact resistance, allowing for direct metal-to-metal contact between the terminal and skeleton, thereby minimizing energy loss while maintaining reliable electrical connection.
Data Source
AI summary
The present disclosure discloses an electric energy transmission connecting device and a vehicle, including at least one electric connection skeleton and connectors connected to two ends of the electric connection skeleton, and the connector is internally provided with at least one fixing cavity, an end portion of the electric connection skeleton extends to form terminal structure, at least a part of the terminal structure is arranged in the fixing cavity, and the terminal structure achieves an electric connection function of the connector. According to the electric energy transmission connecting device in the present disclosure, the terminal structure and the electric connection skeleton can be prevented from being broken due to vibration in a use process, and the stability of which is enhanced.