Insulated Clamping Screw Head for Shielded High-Current Connectors
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Solution Overview
Problem
Existing high-current screw contact connections in electrical connectors face challenges in maintaining robustness, ease of handling, and durability under harsh environmental conditions, particularly in hybrid and electric vehicles, while ensuring safe and efficient transmission of high electrical currents and voltages.
Innovation Solution
A clamping screw device with an electrical insulation on the screw head, incorporating electromagnetic shielding and/or a seal, is designed to enhance the mechanical and electrical integrity of high-current connections, eliminating material transfer through holes and improving vibration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If screwable connections are used for high-current electrical connectors, then mechanical assembly and disassembly are enabled, but material transfer issues occur through holes in the screw connections
Solution Approach 1:
The patent removes the harmful holes from the screw connection structure by using a solid cylindrical screw design without through-holes. The screw engages with threaded bores in the contact devices, eliminating the material transfer pathway while maintaining mechanical assembly capability
Solution Approach 2:
The patent introduces threaded bores as an intermediary structure between the screw and the contact devices. These threaded bores provide mechanical engagement without requiring through-holes that would allow material transfer, thus mediating between the need for assembly and the need to prevent contamination
2Reliability
If additional components are added to prevent material transfer, then safety is improved, but device complexity increases
Solution Approach 1:
The patent combines the screw head, electromagnetic shielding, and seal into a single integrated component. The screw head itself is designed to provide electromagnetic shielding and sealing functions, eliminating the need for separate components and reducing overall device complexity while maintaining safety
Solution Approach 2:
The screw head is designed to perform multiple functions simultaneously: mechanical fastening, electromagnetic shielding, and sealing. This multi-functional design eliminates the need for additional components, reducing complexity while improving safety through integrated protection
3Object-affected harmful factors
If electromagnetic shielding and seal are added to the screw head, then protection against harmful factors is improved, but manufacturing complexity increases
Solution Approach 1:
The electromagnetic shielding and seal are integrated directly into the screw head structure as a single molded component. This merging of functions into one manufacturing process reduces overall manufacturing complexity compared to assembling multiple separate shielding and sealing components
Solution Approach 2:
The screw head is manufactured as a composite structure with different material properties in different regions - conductive material for electromagnetic shielding and elastomeric material for sealing. This composite approach allows both protection functions to be achieved in a single component through advanced manufacturing techniques
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 robust, easily separable, and shockproof connection capable of handling high currents and voltages, with improved durability and safety features, suitable for dynamic vehicle operations and varying environmental conditions.
Implementation Method 1
The electrical insulation accommodates an electromagnetic shielding and/or a seal
Implementation Method 2
The electrical insulation accommodates an electromagnetic shielding and/or a seal
Data Source
AI summary
A clamping screw device has a clamping screw extending in an axial direction and including a screw head that is rotatable, a screw body, and a screw foot. The clamping screw device has an electrical insulation on an outside of the screw head. The electrical insulation accommodates an electromagnetic shielding and/or a seal.