Power Connector Alignment Body With Elongated Slot
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power connector assemblies face issues with alignment and stress distribution, leading to potential misalignment and deformation of the alignment plate, which can affect the secure transmission of electrical current.
Innovation Solution
A power connector assembly featuring a power contact with opposing contact springs and a support plate with an elongated slot, where the contact springs extend parallel to the slot, and a coupling member holds the power contact in a designated position, allowing for proper alignment and stress distribution, reducing the risk of misalignment and deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the power contact is positioned entirely above the plate and secured through a common fastener, then the alignment plate can guide and protect the busbar, but the panel extension may crack or deform, reducing the securing force and affecting electrical current transmission
Solution Approach 1:
The invention divides the alignment plate into two separate components: the alignment plate itself and the mounting bracket. The mounting bracket is attached to the alignment plate and provides the fastening function, while the alignment plate focuses on guiding and aligning the busbar. This segmentation prevents the panel extension from bearing both alignment and fastening loads, eliminating the risk of cracking or deformation.
Solution Approach 2:
The mounting bracket acts as an intermediary component between the alignment plate and the power contact. It provides the fastening function that was previously integrated into the alignment plate's panel extension, allowing the alignment plate to maintain its structural integrity while still securing the power contact through the mounting bracket.
2Manufacturing precision
If the alignment plate is used to guide and protect the busbar, then misalignment is corrected, but the plate thickness and power contact height increase the device's available space requirements
Solution Approach 1:
The invention introduces a third dimension by positioning the power contact below the alignment plate rather than above it. This vertical arrangement allows the alignment plate and power contact to occupy different vertical spaces, optimizing the use of available space and reducing the device's overall footprint while maintaining alignment functionality.
3Ease of operation
If the contact springs oppose each other with a receiving space, then the busbar can be engaged, but misalignment may cause the busbar to be directed improperly or overstress the contact springs
Solution Approach 1:
The alignment plate with its elongated slot performs the preliminary action of aligning the busbar before the busbar engages with the contact springs. The elongated slot guides the busbar into the correct position, ensuring proper alignment before the contact springs apply their clamping force, thereby preventing overstress and ensuring reliable engagement.
Data Source
AI summary
Power connector assembly including a power contact having a base portion and opposing contact springs that project from the base portion along a mating axis. The contact springs oppose each other across a receiving space and are configured to engage a common conductive component that is inserted into the receiving space in a direction along the mating axis. The power connector assembly also includes an alignment body that has a support plate and a coupling member that engages and holds the power contact. The support plate includes an elongated slot and a contact window. The coupling member holds the power contact in a designated position relative to the support plate, wherein the base portion extends into the contact window when in the designated position and the contact springs extend along and substantially parallel to the elongated slot when in the designated position.