Power Connector with Vulcanized Rubber Body for High-Voltage Isolation
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Solution Overview
Problem
Existing power connectors for new energy vehicles fail to provide a stable and efficient connection between the electronic power control unit and the drive motor unit, while ensuring sealing, shock absorption, and insulation, especially under varying working conditions.
Innovation Solution
A power connector comprising conductive frames made of oxygen-free copper with a rubber body made of silicon rubber, where the frames are arranged in parallel and connected by vulcanization, featuring sealing ribs and protrusions for secure positioning and insulation, and a multi-stage hem design to prevent interference, with tin-plated surfaces for improved conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conductive frames are arranged in parallel for high-voltage power transmission, then power transmission efficiency is improved, but spacing problems and positioning stability problems occur leading to arcing and breakdown
Solution Approach 1:
A rubber body serves as an intermediary substance between parallel conductive frames, providing both spacing maintenance and positioning stability. The rubber body prevents direct contact between frames while maintaining fixed distances, thereby preventing arcing and breakdown during high-voltage power transmission.
Solution Approach 2:
The connector combines conductive frames (metal material for electrical conductivity) with a rubber body (insulating material for spacing and stability). This composite structure achieves both efficient power transmission through the conductive frames and reliable positioning through the insulating rubber body.
2Reliability
If conductive frames are spaced apart to prevent contact, then insulation is improved, but positioning stability deteriorates due to spacing problems
Solution Approach 1:
The rubber body merges multiple functions into a single component: it provides insulation between conductive frames, maintains fixed spacing, and ensures positioning stability. This unified structure eliminates the trade-off between insulation and positioning stability.
3Device complexity
If a simple connector structure is used, then device complexity is reduced, but sealing and shock absorption functions are insufficient
Solution Approach 1:
The rubber body performs multiple functions simultaneously: sealing (preventing fluid ingress), shock absorption (damping mechanical impacts), and positioning (maintaining frame spacing). This multi-functional design achieves comprehensive reliability without significantly increasing structural complexity.
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 power connector effectively prevents arcing and breakdown during high-voltage power transmission, ensuring stable and secure connections with sealing, insulation, and damping functions, facilitating efficient power transmission between the electronic and drive motor units.
Implementation Method 1
the rubber body prevents arcing and breakdown of adjacent conductive frames due to spacing problems and positioning stability problems during high-voltage power transmission
Implementation Method 2
the functions of fixing, sealing, insulating and damping can be realized
Data Source
AI summary
Provided is a power connector, including a plurality of conductive frames and a rubber body, the first connecting hole is opened at one end of the conductive frame, and the second connecting hole is opened at the second end of the conductive frame, the plurality of conductive frames are arranged in parallel and spaced apart by a predetermined distance, and the middle portions of the plurality of conductive frames are connected by rubber vulcanization to form the rubber body. The power connector is provided in the present application, the rubber body isolates and fixes a plurality of conductive frames to form a power connector, the rubber body prevents arcing and breakdown of adjacent conductive frames due to spacing problems and positioning stability problems during high-voltage power transmission.