Laminar Electrical Connector Without Sheath
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Solution Overview
Problem
Conventional electrical connectors for electric and hybrid vehicles face inefficiencies due to current concentration around sheaths or grommets, leading to localized heating, mechanical failures, and weight considerations, which existing connectors cannot adequately address.
Innovation Solution
A laminar electrical connector is designed without a sheath or grommet, formed from superimposed conductive strips with a lower melting temperature material layer between them, enhancing conductivity and delamination strength through resistive heating, and using polymeric insulators to improve performance and longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a sheath or grommet is used to surround the connector hole, then mechanical protection is improved, but current concentration and localized heating occur that reduce electrical efficiency and connector longevity
Solution Approach 1:
The patent removes the sheath or grommet from the connector design entirely. The laminar connector consists of multiple superimposed conductive strips without any surrounding protective sheath, thereby eliminating the source of current concentration and localized heating while maintaining mechanical integrity through the laminar structure itself
Solution Approach 2:
The patent uses multiple superimposed strips of conductive material with different properties. The combination of conductive strips creates a composite structure that provides both electrical conductivity and mechanical strength without requiring a separate sheath material, distributing current evenly across the laminar interface
2Strength
If a sheath or grommet is used to surround the connector hole, then mechanical protection is improved, but the operative lifetime of the connector is reduced due to material interface failures
Solution Approach 1:
The patent eliminates the sheath or grommet component entirely, removing the additional material interfaces that are prone to failure. The connector consists only of the superimposed conductive strips, reducing the number of potential failure points and improving long-term reliability
Solution Approach 2:
The patent combines the structural and electrical functions into a single integrated laminar structure. The conductive strips themselves provide both the mechanical connection and electrical conductivity, eliminating the need for separate protective materials and reducing interface complexity
3Ease of manufacture
If conventional connector design with sheath is used, then ease of manufacture is maintained, but weight is increased and performance in vehicle applications is insufficient
Solution Approach 1:
The patent divides the connector into multiple thin superimposed strips rather than using a single solid piece with a sheath. This segmentation allows for lighter weight while maintaining strength through the distributed laminar structure, and the strips can be manufactured and assembled relatively easily
Solution Approach 2:
The patent uses a composite laminar structure of multiple conductive strips that provides high strength-to-weight ratio. The thin superimposed layers create a lightweight connector suitable for vehicle applications while maintaining ease of manufacture through standard laminar fabrication processes
4Ease of manufacture
If conventional connector design is used, then existing manufacturing processes are maintained, but localized heating changes connector metal temper and reduces performance
Solution Approach 1:
The patent removes the sheath or grommet that causes current concentration, thereby eliminating the source of localized heating. The direct contact between superimposed conductive strips distributes current evenly across the interface, preventing hot spots that would alter metal temper
Solution Approach 2:
The patent creates a uniform current distribution across the entire interface between superimposed strips. Each local area of the laminar interface handles current evenly without concentration, preventing localized heating and temper changes in any specific region of the connector
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 superior current flow and mechanical strength, reducing the risk of mechanical failure and improving efficiency by eliminating the limitations of sheaths and grommets, while being easier to manufacture and suitable for vehicle applications.
Implementation Method 1
Resistive heating of the stack to a temperature greater than two thirds of the second material melting temperature and less than the first conductive material melting temperature increases electrical conductivity and delamination strength of the stack
Data Source
AI summary
A laminar electrical connector is provided that is formed from multiple superimposed strips of conductive material that form a stack having at least two ends. A second conductive material is used to join adjacent superimposed strips. The resultant connector has ends that are adapted to engage electrical terminals and provide an electrical communication therebetween. The resultant connector lacks a sheath on the ends or a grommet extending through the stack. Such a sheath or grommet limits the operative lifetime of the resulting connector and also creates current focusing that diminishes overall connector efficiency. A connector having a continuous layer of the second conductive material joining adjacent strips along the entire interface between the adjacent strips is also provided and improves connector performance in ways that are especially beneficial to applications associated with an electric vehicle or a hybrid vehicle.