Laminated Power Connector Assembly for Even Cantilever Loading
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Solution Overview
Problem
The uneven distribution of forces on cantilevers in existing power connectors, such as those with slat-shaped terminals, can lead to damage and failure, compromising durability and structural integrity.
Innovation Solution
A power connector design featuring symmetrical first and second connecting arms with constant widths, coupled by locking pieces and fasteners, ensures even force distribution and secure attachment, enhancing durability and structural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If cantilevers are arranged with increasing perpendicular distance from the central portion, then the terminal structure can accommodate plate-type bus bar, but the force distribution on cantilevers becomes uneven leading to potential failure
Solution Approach 1:
The patent applies asymmetry by intentionally designing the cantilevers with non-parallel arrangements where the perpendicular distance between adjacent cantilevers increases gradually from the central portion. This asymmetric geometry allows the terminal structure to accommodate plate-type bus bar effectively while the increasing distance distribution helps balance the force distribution across cantilevers, preventing any single cantilever from bearing excessive load.
2Strength
If fasteners penetrate through multiple conductive pieces and locking pieces, then secure attachment is achieved, but the manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the terminal assembly into distinct modular components: multiple conductive pieces with through holes, fasteners, and locking pieces with bodies. This segmentation allows each component to be manufactured separately with standard through-hole patterns, then assembled together. The modular design achieves strong structural attachment while simplifying manufacturing and assembly processes compared to integrated designs.
Data Source
AI summary
A power connector includes at least one terminal assembly, a plurality of fasteners and a pair of locking pieces. The terminal assembly includes a terminal structure. The terminal structure includes a plurality of conductive pieces. Each of the conductive pieces has a plurality of first through holes. Each of the fasteners penetrates through a corresponding one of the first through holes of each of the conductive pieces to secure the conductive pieces in a laminated manner. Each of the locking pieces includes a body. The body is configured to at least partially abut against one of outermost two of the conductive pieces. The body has a plurality of second through holes. Each of the fasteners further penetrates through a corresponding one of the second through holes to secure the body on the conductive pieces.