Laminated Plug-In Terminal Assembly for High-Current Maintenance
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Solution Overview
Problem
Existing terminals are costly, have low production efficiency, limited current carrying capacity, and are difficult to maintain due to welding fixation, while sheet-like laminated terminals offer a promising solution but require improved assembly and maintenance methods.
Innovation Solution
A plug-in terminal design with laminated sheet-like terminals featuring cantilevered arms and buckles for assembly, allowing for increased contact area and ease of maintenance, utilizing symmetrically disposed contact and cantilever structures, and elastic fixing mechanisms for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional machining methods are used to form terminals, then structural strength is improved, but manufacturing cost increases and production efficiency decreases
Solution Approach 1:
The terminal is divided into multiple thin-walled laminated sheets stacked together, where each sheet contains contact portions and cantilevers. This segmentation allows for simpler manufacturing of individual sheets while maintaining overall structural strength through the stacked configuration.
Solution Approach 2:
Multiple thin-walled laminated sheets are stacked and fixed together to form a composite terminal structure. The composite construction combines the simplicity of sheet metal fabrication with the strength of a multi-layer assembly, achieving both cost-effectiveness and mechanical integrity.
2Strength
If traditional machining methods are used to form terminals, then structural strength is improved, but manufacturing cost increases
Solution Approach 1:
The terminal is divided into multiple thin-walled laminated sheets stacked together, where each sheet contains contact portions and cantilevers. This segmentation allows for simpler manufacturing of individual sheets while maintaining overall structural strength through the stacked configuration.
Solution Approach 2:
Multiple thin-walled laminated sheets are stacked and fixed together to form a composite terminal structure. The composite construction combines the simplicity of sheet metal fabrication with the strength of a multi-layer assembly, achieving both cost-effectiveness and mechanical integrity.
3Strength
If welding is used to fix sheet terminals, then connection strength is improved, but maintenance difficulty increases
Solution Approach 1:
The terminal assembly is segmented into multiple independently stackable laminated sheets with buckle structures, allowing individual sheets to be replaced without affecting the entire assembly. This modular design enables easy maintenance while maintaining connection strength through the buckle fixation system.
4Reliability
If contact area is increased to improve current carrying capacity, then current carrying capacity is improved, but device complexity increases
Solution Approach 1:
The contact area is increased by stacking multiple thin-walled laminated sheets in the transverse direction, utilizing the third dimension (depth/layering) rather than expanding the surface area in two dimensions. This approach increases current carrying capacity while maintaining a compact and simple terminal structure.
Solution Approach 2:
Multiple laminated sheets with contact portions and cantilevers are merged into a single stacked assembly, creating a unified terminal structure that achieves high current carrying capacity through the combined contact area of all sheets while maintaining structural simplicity.
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, facilitates easy assembly, reduces maintenance costs, and ensures reliable electrical connections with adaptable plug-in directions, while maintaining structural integrity and cost-effectiveness.
Implementation Method 1
a protruding contact portion and a protruding cantilever with elastic are sequentially disposed from a free end of the plug-in arm to the laminate base body
Data Source
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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.