Plug-Type Electrical Connection Wedge Clamping
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Solution Overview
Problem
Existing plug-in contact systems in power electronics suffer from poor electrical and thermal conductivity due to small contact surfaces, leading to high resistance and limited current carrying capacity, and are inadequate in withstanding vibration loads and high temperatures, with assembly requiring significant force and tool access.
Innovation Solution
A plug-in connection system utilizing a contact bolt or sleeve with a collet or clamping bolt, providing a large planar contact area for low assembly force and high conductivity, preventing relative movement through a wedge effect, and allowing concealed assembly without tool access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional spring contacts with small contact surfaces are used, then the contact system can be compact, but the electrical and thermal resistance increases leading to strong heating
Solution Approach 1:
The patent merges multiple contact surfaces into a single large-area planar contact interface between the contact bolt and collet. Instead of separate point or line contacts, the entire contact surface area is utilized to create a large-area electrical and thermal conduction path, reducing resistance and heating while maintaining compact dimensions
Solution Approach 2:
The patent transitions from point or line contact (zero-dimensional or one-dimensional contact area) to planar surface contact (two-dimensional contact area). This dimensional change dramatically increases the effective contact area for electrical and thermal conduction without significantly increasing the overall volume of the contact system
2Ease of operation
If plug contacts are used for concealed assembly, then tool access is not required, but the vibration resistance is insufficient for automotive applications
Solution Approach 1:
The patent employs conical surfaces with precise angular geometry to create a wedge effect. The conical clamp surface and corresponding conical contact surface generate radial clamping forces that securely hold the contact bolt, preventing relative movement under vibration while allowing simple push-in assembly without tools
Solution Approach 2:
The wedge effect mechanism automatically generates the necessary clamping force during the insertion process itself. As the contact bolt is pushed into the collet, the conical surfaces convert the axial insertion force into radial clamping force, securing the connection without requiring additional fastening operations or tool access
3Device complexity
If point or line contact surfaces are used, then the contact system structure is simple, but the current carrying capacity is limited due to high resistance
Solution Approach 1:
The patent combines multiple contact elements into a unified large-area planar contact interface. The contact bolt and collet are designed with mating conical surfaces that create an extended contact area, merging what would otherwise be separate point or line contacts into a continuous surface for current flow, thereby reducing resistance and increasing current carrying capacity
Solution Approach 2:
The patent utilizes highly conductive copper or aluminum materials for the contact surfaces. These high-conductivity materials are specifically selected and applied to the contact bolt and collet surfaces to minimize electrical and thermal resistance, enabling high current carrying capacity while maintaining structural integrity
4Reliability
If large clamping forces are required for vibration resistance, then the connection reliability improves, but the assembly force required increases beyond manual assembly limits
Solution Approach 1:
The patent employs conical surfaces with optimized angle geometry to create a mechanical wedge effect. This wedge mechanism efficiently converts small axial insertion forces into large radial clamping forces during assembly, achieving vibration-resistant connection reliability while keeping the required assembly force within manual handling limits of less than 75 N
Solution Approach 2:
The clamping force is generated dynamically during the insertion process rather than requiring pre-applied static force. As the contact bolt is inserted into the collet, the conical surfaces progressively generate increasing clamping force, with the maximum clamping force achieved automatically at full insertion without requiring sustained high assembly force
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 system achieves low electrical and thermal resistance, high vibration tolerance, and reduced assembly force, enabling efficient electrical connections with low overall height and high current carrying capacity.
Implementation Method 1
The wedge effect creates large clamping forces, which even prevent relative movements in the μ range
Implementation Method 2
According to the invention, there is no point or line contact, but rather a planar contact. At the same time, it is not a conventional spring contact, so that the system according to the invention can be plugged in with very little force. Highly conductive copper or aluminum can be used for the base material, resulting in very low electrical and thermal contact resistance
Implementation Method 3
Highly conductive copper or aluminum can be used for the base material, resulting in very low electrical and thermal contact resistance
Data Source
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AI summary
The present invention relates to a plug-type connection (1) for an electrical connection between a first line (2) and a second line (3), comprising a contact bolt (4) which can be connected to the first line (2), a collet (5) which can be connected to the second line (3) and has a cutout (6) for inserting the contact bolt (4), has a conical collet outer face (7) and has at least n slots (8) for forming n clamping jaws, where n ≥ 1, and a clamping ring (9) with a conical clamping ring inner face (10) against which the conical collet outer face (7) bears, wherein the at least one clamping jaw can be clamped against the contact bolt (4) as a result of a relative movement between the collet (5) and the clamping ring (9).