Compliant HV Terminal Insert for Low-Resistance Multi-Point Contact
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Solution Overview
Problem
High voltage electrical terminals face challenges in achieving low contact resistance and resilience to unintended decoupling, particularly at elevated temperatures, while also being cost-effective and requiring minimal plating, especially when using aluminum bus bars.
Innovation Solution
The design incorporates a U-shaped retainer with a spring and a contact insert featuring an array of resilient protrusions that work in conjunction with projections to establish multiple connection points, reducing the need for expensive plating materials by distributing contact force effectively and maintaining low resistance across multiple contact points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminals are plated with low electrical resistance material such as silver or gold, then contact resistance is reduced, but manufacturing time and cost increase
Solution Approach 1:
The contact surface is segmented into multiple contact bumps (at least two) instead of a single large contact area. This segmentation creates multiple parallel current paths, reducing overall contact resistance without requiring expensive plating materials on the entire surface.
Solution Approach 2:
The contact bumps are strategically positioned and sized to concentrate contact force at specific high-value locations. This local quality approach ensures low contact resistance at critical points while avoiding the need to plate entire terminal surfaces with expensive materials.
2Reliability
If copper-based lamella contact inserts are used to provide multiple contact points, then contact resistance is reduced, but spring force relaxes at elevated temperatures
Solution Approach 1:
The terminal structure combines copper-based contact bumps (for low electrical resistance) with a steel body (for thermal stability and mechanical strength). This composite approach allows the contact elements to maintain low resistance while the overall structure resists thermal relaxation and maintains spring force at elevated temperatures.
3Reliability
If the number of contact points is increased to reduce contact resistance, then electrical performance improves, but manufacturing complexity increases
Solution Approach 1:
The contact surface is divided into multiple discrete contact bumps that can be formed through standard stamping or molding processes. This segmentation achieves multiple contact points using conventional manufacturing techniques, avoiding excessive complexity while maintaining low contact resistance.
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 configuration significantly reduces contact resistance, enhances resilience to overstress, and simplifies manufacturing by eliminating the need for costly plating, while maintaining reliability across varying temperatures and currents.
Implementation Method 1
a spring that extends from a wall of the U-shaped retainer and applies a normal force to couple a terminal to a mating terminal
Implementation Method 2
a contact insert configured to be arranged between the terminal and the mating terminal, wherein the contact insert includes an array of resilient protrusions that operate in conjunction with at least one projection that extends from the terminal to establish a plurality of connection points
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A high-voltage electrical connector is described. The connector includes a U-shaped retainer and a spring that extends from a wall of the U-shaped retainer and applies a normal force to couple a terminal to a mating terminal in the high voltage electrical connector. The connector further includes a contact insert configured to be arranged between the terminal and the mating terminal. The contact insert includes an array of resilient protrusions that operate in conjunction with at least one projection that extends from the terminal to establish a plurality of connection points between the terminal and the mating terminal.