Modular Electric Connection Device with Segmented Conductors
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Solution Overview
Problem
Existing methods for manufacturing electrical connection devices result in high scrap rates and high material costs due to inefficient use of materials, particularly in the production of connecting combs.
Innovation Solution
A method involving the folding and shaping of conductive wires to form teeth, with mechanical and electrical connection between conductors made from copper-plated or non-copper plated aluminum, allowing for optimized section values to minimize material usage and costs, using brazing or welding for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a strip of copper is used to manufacture connecting combs by cutting and folding, then the electrical connection function is achieved, but the scrap rate reaches around 50% and the cost price becomes particularly high
Solution Approach 1:
The invention divides the connection device into two separate functional parts: a first conductor made of copper-plated aluminum for current transport, and a second conductor made of solid copper for electrical connection and distribution. This segmentation allows each material to be optimized for its specific function, reducing overall material waste while maintaining manufacturing efficiency.
Solution Approach 2:
The invention employs composite materials by using copper-plated aluminum for the first conductor (combining copper's conductivity with aluminum's lightness and cost-effectiveness) and solid copper for the second conductor where high conductivity is critical. This strategic material selection reduces scrap rates and manufacturing costs while preserving essential electrical connection functions.
2Reliability
If copper is used for the entire connection device, then excellent electrical conductivity is achieved, but the material cost increases significantly
Solution Approach 1:
The invention applies different material qualities to different parts of the connection device based on local functional requirements. The first conductor uses copper-plated aluminum where moderate conductivity suffices for current transport, while the second conductor uses solid copper where high conductivity is essential for connection and distribution, thereby optimizing material cost while maintaining overall electrical reliability.
Solution Approach 2:
The invention changes the material composition parameter of the conductors based on their specific functions. By using copper-plated aluminum (10-20% copper in section) for the first conductor and solid copper for the second conductor, the invention optimizes the balance between electrical conductivity and material cost, reducing overall copper consumption while maintaining necessary electrical performance.
3Quantity of substance
If aluminum conductor is used for the first part, then material cost is reduced, but the section value must be multiplied by approximately 1.6 compared to copper to carry the same current
Solution Approach 1:
The invention uses copper-plated aluminum for the first conductor, combining aluminum's cost-effectiveness and light weight with copper's superior conductivity through plating. This composite material approach allows the conductor to carry the required current with a smaller cross-sectional area compared to pure aluminum, while maintaining lower material costs and reduced volume compared to solid copper.
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 method reduces material waste and costs by approximately 50% while maintaining effective electrical conductivity, enabling efficient production of connection devices for various calibers without generating excess material.
Implementation Method 1
the first part is made from a copper-plated or non-copper-plated aluminum conductor wire, while the second part is made from a copper-plated aluminum conductor wire, or solid copper
Implementation Method 2
the mechanical and electrical assembly of the two aforementioned conductors is carried out by brazing or welding
Implementation Method 3
the mechanical and electrical assembly of the two aforementioned conductors is carried out by brazing or welding
Data Source
Figure 1~2
AI summary
The method involves providing two distinct conducting wires (4, 5) that are utilized for separating a current carrying part (1) and a power distribution part (2) that is arranged for distribution of power to modular electrical appliances. A set of teeth (3) is mechanically and electrically connected to the distinct conducting wires. The function of distribution of power to the electrical appliances is performed by the conducting wire having a larger size, and the function of connection of terminals of the appliances is performed by the wire having a smaller size. An independent claim is also included for an electric connection device.