Power Connector Module With Adjustable Shell Spacing
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Solution Overview
Problem
Existing power connectors require fixed-size metal shells and riveted nuts, leading to increased costs due to the need for multiple shell sizes and specialized tools for assembly.
Innovation Solution
An electrical connection module with adjustable shell spacing and nut-less assembly using fasteners and thermal blocks with adjustable thickness, allowing interchangeable terminals and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the metal shell is made as an integral piece with fixed distance between top and bottom walls, then the structural strength is improved, but the adaptability to different terminal thicknesses deteriorates
Solution Approach 1:
The metal shell is divided into upper and lower halves that can be relatively moved along the vertical direction. The separation line between the two halves allows the distance between top and bottom walls to be adjusted, enabling adaptation to different terminal thicknesses while maintaining structural integrity through the segmented design
2Reliability
If the nut is riveted onto the metal shell to prevent movement, then the connection reliability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The nut is designed with a self-locking structure that automatically prevents movement without requiring riveting. The nut's inherent design features enable it to maintain its position on the metal shell through its own structural characteristics, eliminating the need for additional riveting operations and specialized tools
3Reliability
If the nut is riveted onto the metal shell to ensure connection reliability, then the connection stability is improved, but the ease of manufacture deteriorates
Solution Approach 1:
The self-locking nut design allows workers to install the nut without requiring riveting tools or specialized skills. The nut automatically secures itself to the metal shell through its built-in locking mechanism, making the assembly process simpler and more accessible to general workers
4Adaptability or versatility
If metal shells of different sizes are manufactured to match mating terminals of different thicknesses, then the adaptability is improved, but the manufacturing cost increases
Solution Approach 1:
A single universal metal shell design with adjustable upper and lower halves can accommodate multiple terminal thicknesses. By allowing relative movement between the upper and lower halves, one shell can serve multiple functions and adapt to different terminal specifications, eliminating the need to manufacture multiple shell sizes
Data Source
AI summary
An electrical connection module includes a shell, a terminal arranged in the shell, and a thermal block disposed in the shell. The shell has a front port, an upper shell, a lower shell opposite the upper shell in a height direction of the shell, a front end, and a rear end opposite the front end in a longitudinal direction of the shell. The terminal has an upper terminal and a lower terminal opposite each other in the height direction. The upper terminal and the lower terminal respectively have an upper elastic contact arm and a lower elastic contact arm located in the front port. The thermal block is clamped between the upper terminal and the lower terminal. The upper elastic contact arm and the lower elastic contact arm electrically contact an upper side and a lower side of a mating terminal inserted into the front port.