Pluggable Current Transmission Assembly for 100 A Connectors

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Solution Overview

Problem

Conventional current transmission assemblies are insufficient in carrying high currents due to limitations in terminal structure design, necessitating an enhancement in current carrying capacity.

Innovation Solution

A current transmission assembly featuring a pluggable component with conductive arms, connecting members, and electrically connecting components, including a conductive main body with a connecting portion and through hole, and a wire main body with exposed terminals fused together, allowing increased current transmission.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If conventional terminal structure design is used, then the device complexity is low, but the current carrying capacity is insufficient

Engineering Contradiction:
Improvecurrent carrying capacityVSAvoidterminal structure complexity
Core Design Contradiction:
Quantity of substanceVSDevice complexity

Solution Approach 1:

The terminal structure is divided into multiple electrically conductive arms (first conductive arm, second conductive arm, third conductive arm, fourth conductive arm) with separate contact terminals. Each arm can independently carry current, effectively segmenting the current path to increase overall current carrying capacity while maintaining manageable structural complexity through modular design

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent transitions from conventional single-plane terminal arrangements to a three-dimensional configuration where contact terminals are positioned at different spatial locations and orientations. The electrically conductive arms extend in multiple directions from the housing, creating a multi-dimensional current transmission pathway that increases capacity without proportionally increasing structural complexity

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

2Quantity of substance

If the cross-sectional area of terminal structure is increased, then current carrying capacity improves, but the device volume increases

Engineering Contradiction:
Improvecurrent carrying capacityVSAvoidterminal structure volume
Core Design Contradiction:
Quantity of substanceVSVolume of stationary object

Solution Approach 1:

Instead of increasing cross-sectional area in a single plane, the patent utilizes three-dimensional space by positioning contact terminals at different heights and angles. The electrically conductive arms extend outward and upward from the housing, creating vertical and angular separation that increases effective current carrying capacity without proportionally increasing overall volume

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The electrically conductive arms are nested within or around the housing structure, with some arms positioned inside the housing and others extending outward. This nested arrangement allows multiple current paths to share the same volumetric space, increasing current carrying capacity while minimizing the increase in overall device volume

Inventive Principle:
Principle #7Nested doll (Nesting)

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 enhanced design significantly increases the current carrying capacity, enabling the transmission of currents exceeding 100 A by improving the structural integrity and contact efficiency between components.

Implementation Method 1

at least one part of the plurality of electrically conductive fibers that are exposed from the second terminal are welded to each other

Methodology Applied
Scientific EffectWelding: Welding

Implementation Method 2

The second terminal of the wire main body is fixed to the connecting portion by ultrasonic welding or by soldering

Methodology Applied
Scientific EffectUltrasonic welding: Ultrasonic Vibration

Data Source

PatentUS11888252B2Current transmission assembly and current transmission system
Publication Date: 2024.01.30 BELLWETHER ELECTRONICS KUNSHAN
  • US11888252B2 patent drawing
  • US11888252B2 patent drawing
  • US11888252B2 patent drawing

AI summary

A current transmission assembly and a current transmission system are provided. The current transmission system includes the current transmission assembly and a circuit board structure. The current transmission assembly includes a pluggable component, at least one conductor component, and at least one electrically connecting component. The pluggable component includes a housing, two sets of electrically conductive arms, and two connecting members. Each of the two sets of electrically conductive arms is disposed inside the housing. Each of the conductor components includes an electrical insulator and a wire main body. The electrical insulator encircles the wire main body, so that a first terminal and a second terminal are exposed from the wire main body, and the first terminal is connected to one of the two connecting members. Each of the electrically connecting components includes a connecting portion, to which the second terminal of the wire main body is fixed.