Laminated Electrical Contact Module for High Current Conduction
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Solution Overview
Problem
Existing electrical contact systems face challenges in efficiently conducting high electrical currents, particularly in applications like electromagnetic projectile launchers and high-energy radars, where they often experience resistance issues and mechanical loading limitations.
Innovation Solution
The development of an electrical contact module comprising a stack of metal laminations with angled fingers and clamping bars, designed to compressively hold the laminations together, allowing for efficient electrical conductivity and high mechanical load-bearing capacity, with configurations adaptable for both translational and rotational movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing electrical contact systems are used to conduct high electrical currents, then electrical conductivity is achieved, but resistance issues and mechanical loading limitations occur
Solution Approach 1:
The electrical contact system is divided into multiple individual laminations (e.g., 10 laminations) stacked together, each lamination being a separate conductive element. This segmentation allows the system to distribute electrical current across multiple parallel pathways, reducing resistance and heat generation, while also distributing mechanical loads across multiple contact points, thereby increasing overall mechanical loading capacity.
Solution Approach 2:
The system uses composite construction by stacking multiple laminations together to form a laminated structure. This composite approach combines the electrical conductivity of individual metal laminations with the mechanical strength provided by the stacked configuration and clamping bars, creating a system that simultaneously achieves high electrical conductivity and high mechanical loading capacity.
2Power
If high electrical currents are conducted through existing contact systems, then electrical power is delivered, but resistance issues arise
Solution Approach 1:
The electrical contact system is divided into multiple individual laminations (e.g., 10 laminations) stacked together, each lamination being a separate conductive element. This segmentation allows the system to distribute electrical current across multiple parallel pathways, reducing resistance and heat generation, while also distributing mechanical loads across multiple contact points, thereby increasing overall mechanical loading capacity.
Solution Approach 2:
The system transitions from a single-plane contact interface to a multi-layered three-dimensional stacked structure. By stacking laminations in the vertical dimension, the system increases the effective contact area and creates multiple parallel current pathways, thereby reducing electrical resistance without increasing the footprint of the contact system.
3Strength
If mechanical loading capacity is increased in existing contact systems, then structural strength is improved, but electrical conductivity is compromised
Solution Approach 1:
The system uses composite construction by stacking multiple laminations together to form a laminated structure. This composite approach combines the electrical conductivity of individual metal laminations with the mechanical strength provided by the stacked configuration and clamping bars, creating a system that simultaneously achieves high electrical conductivity and high mechanical loading capacity.
Solution Approach 2:
The electrical contact system is divided into multiple individual laminations (e.g., 10 laminations) stacked together, each lamination being a separate conductive element. This segmentation allows the system to distribute electrical current across multiple parallel pathways, reducing resistance and heat generation, while also distributing mechanical loads across multiple contact points, thereby increasing overall mechanical loading capacity.
4Stability of the object's composition
If clamping bars are used to compressively hold laminations together, then mechanical stability is improved, but device complexity increases
Solution Approach 1:
The system merges multiple functional elements into an integrated laminated structure. The individual laminations are stacked and compressed together between clamping bars, creating a unified assembly where the laminations provide both electrical conductivity and mechanical stability. This merging approach achieves mechanical stability without requiring complex fastening mechanisms or additional structural components.
Solution Approach 2:
The system uses thin lamination sheets that can be stacked and compressed to form a stable structure. These thin film-like laminations, when compressed between clamping bars, provide both electrical conductivity and mechanical stability through their layered configuration, avoiding the need for bulky or complex structural elements.
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 enables the reliable conduction of electrical currents exceeding 1 million Amps in a pulse duration of less than one second, with enhanced resistance to relative movement and mechanical loading, making it suitable for demanding applications such as railguns and other high-energy systems.
Implementation Method 1
At least a first clamping bar and a second clamping bar parallel to the central longitudinal sections of the plurality of laminations are disposed to compressively hold the plurality of laminations together in a stack disposed between the clamping bars along a clamping axis disposed orthogonal to the primary movement direction
Data Source
AI summary
A system for conducting electricity including a first body, a second body configured to move relative to the first body in a primary movement direction, and one or more electrical contact modules disposed between and in contact with the first body and the second body.