Laminated Plug-In Terminal Structure for High-Current Connector Assembly
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Solution Overview
Problem
Existing high voltage connectors have high costs, low production efficiency, and limited current carrying capacity due to machining-based terminal formation, and their maintenance is challenging due to welding-based fixation.
Innovation Solution
A plug-in terminal and mounting structure featuring laminated sheet-like terminals with a contact portion and cantilever on a plug-in arm, increasing contact area and allowing for easy assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If machining-based terminal formation is used, then manufacturing precision can be achieved, but cost increases and production efficiency decreases
Solution Approach 1:
The patent replaces traditional machining-based terminal formation with a molding process. The terminal body is formed by molding with contact portions and cantilevers integrated into the structure, eliminating the need for subsequent machining operations. This substitution of mechanical machining with molding technology achieves both high manufacturing precision and improved production efficiency.
2Strength
If welding-based fixation is used, then connection strength can be achieved, but ease of repair decreases
Solution Approach 1:
The patent segments the terminal structure into a terminal body and a separate fixing component. The fixing component can be detached and reattached, allowing for easy maintenance and repair while maintaining strong connection strength during operation. This modular design enables replacement of individual components without affecting the entire assembly.
3Weight of moving object
If sheet terminal design is used, then cost and weight are reduced, but contact area with mating terminal is limited
Solution Approach 1:
The patent extends the terminal structure from a simple planar sheet design to a three-dimensional configuration with contact portions and cantilevers that protrude from the terminal body. This dimensional extension increases the contact area with the mating terminal while maintaining the lightweight sheet metal construction and cost-effectiveness of the original design.
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 design enhances current carrying capacity, simplifies assembly, reduces maintenance costs, and adapts to high-current mating terminals with plug-in directions of 90° and 180°.
Implementation Method 1
a protruding cantilever with elastic is sequentially disposed from a free end of the plug-in arm to the laminate base body
Data Source
AI summary
The present disclosure provides a plug-in terminal and a plug-in terminal mounting structure. The plug-in terminal includes: a plurality of laminated terminals stacked in a transverse direction, each of the laminated terminals includes: a laminate base body and plug-in arms longitudinally extending from one end of the laminate base body and disposed to be paired, with a plug-in space formed between the paired plug-in arms; a contact portion protruding toward the plug-in space and a protruding cantilever with elastic are sequentially disposed from a free end of the plug-in arm to the laminate base body; a plurality of the plug-in spaces are stacked in the transverse direction to form a plug-in groove, the plug-in groove is configured to interface with a mating terminal to realize an electrical connection between the plug-in terminal and the mating terminal. By assembling the plurality of sheet-like laminated terminals together, the current carrying capacity is strong and the plug-in terminal is conveniently to be assembled, so that the overall structure is simple and the maintenance cost is low.