Lug-Jaw Connector Reduces Copper in Disconnect Assemblies
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Solution Overview
Problem
Existing disconnect assemblies for air conditioning systems are overly complex and expensive due to excessive use of copper and numerous parts, leading to inefficiencies in current delivery and heat generation at electrical joints.
Innovation Solution
A disconnect assembly with a pullout assembly featuring metal blades and a base assembly with a lug-jaw connector using a half jaw that requires less copper, secured through friction or screws, reducing the number of parts and transitions, allowing for efficient electrical connection and disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If full jaws made of copper are used to make electrical connections, then reliable electrical connection is achieved, but copper usage and cost increase significantly
Solution Approach 1:
The patent divides the traditional full copper jaw into two separate components: a copperlug and an aluminum half jaw. The copperlug provides the electrical connection point, while the half jaw completes the circuit path. This segmentation allows each component to be made from the most appropriate material, reducing overall copper usage while maintaining connection reliability.
Solution Approach 2:
The patent merges the copperlug and half jaw into a single integrated electrical connection system. The half jaw is positioned between the copperlug and the blade, creating a unified connection structure that combines the advantages of both materials - copper's conductivity at the lug and aluminum's lightweight properties at the jaw portion.
2Reliability
If numerous parts including multiple connectors and fasteners are used, then secure electrical connection is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the connector function and the electrical connection function into a single half jaw component. The half jaw serves both as the electrical conductor and as the mechanical connector that secures the blade, eliminating the need for separate 90-degree connectors and reducing the total number of parts.
Solution Approach 2:
The half jaw is designed to perform multiple functions simultaneously: it provides the electrical conduction path, mechanically secures the blade through friction fit, and serves as the interface between the copperlug and the blade. This multi-functionality reduces the need for specialized components for each function.
3Adaptability or versatility
If multiple joints and transitions are created in the electrical path, then flexible connection is achieved, but heat generation increases due to current crowding
Solution Approach 1:
The patent removes the unnecessary 90-degree connector that created an additional joint in the electrical path. By taking out this intermediate component, the electrical current flows more directly from the copperlug through the half jaw to the blade, reducing the number of transitions and minimizing current crowding effects that generate heat.
4Reliability
If traditional disconnect assembly design is used, then adequate electrical connection is achieved, but the amount of copper required is excessive and cost prohibitive
Solution Approach 1:
The patent segments the electrical connection path into distinct material zones: copper at the lug where high conductivity is most needed, and aluminum at the jaw portion where structural properties are more important. This segmentation optimizes material usage by placing each material where it provides the most value, significantly reducing total copper quantity while maintaining adequate electrical connection.
Data Source
AI summary
A disconnect assembly for making and breaking electrical connections to an electrical circuit. The disconnect assembly includes a pullout assembly and a base assembly. The pullout assembly has downwardly facing extensions with slits in them to receive a blade that is inserted securely through the slits. The exposed portions of the blade are received in corresponding lug-jaw connectors in the base assembly. The lug-jaw connectors have a lug and a half jaw attached to the lug. The half jaw has a curved clip portion that opposes a side surface of the lug such that the exposed portion of the blade is received between the clip portion and the side surface, thereby resulting in minimal use of conductive material for the disconnect assembly.