Quarter-Turn Electrical Connector for Larger High-Current Contacts
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Solution Overview
Problem
Current connectors are unable to accommodate larger contact elements required for increased electrical power transmission, particularly in aircraft with hybrid or hydrogen propulsion systems, limiting current capacity to around 46 amps.
Innovation Solution
A connector design featuring rotationally locked assembly with a quarter-turn lock mechanism, incorporating insulating sealing inserts and snap-on means, allowing larger contact elements without the need for a tool, and accommodating currents exceeding 46 amps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a tool passage is provided in the connector body to allow removal of contact elements, then contact elements can be removed and replaced, but the connector cannot accommodate larger contact elements required for increased electrical power transmission
Solution Approach 1:
The patent replaces the traditional tool-based mechanical release system with a quarter-turn locking mechanism. The contact element is secured by a detent ball that engages with a cam groove, allowing the contact to be locked and unlocked by rotating the connector body 90 degrees. This eliminates the need for a tool passage and enables larger contact elements to be accommodated without compromising the removable feature.
2Volume of moving object
If the connector body is made compact to reduce space occupation, then space efficiency is improved, but insulation and sealing between contact elements and connector body becomes more difficult
Solution Approach 1:
The patent employs nested insulating structures where insulating inserts are positioned within the connector body cavity. These inserts are received by dedicated recesses in the connector body, creating a nested arrangement that provides effective insulation and sealing without increasing the overall connector volume. The insulating insert fits inside the connector body's internal space, maintaining compact dimensions while ensuring electrical isolation.
3Ease of operation
If snap-locking means are used to retain contact elements, then contact elements can be easily retained and released, but space must be left for tool passage which limits contact element size
Solution Approach 1:
The patent replaces the snap-locking mechanism requiring tool insertion with a quarter-turn cam-based locking system. The cam groove and detent ball mechanism allows the contact element to be locked in place and released by simply rotating the connector body 90 degrees, eliminating the need for tool passages and enabling larger contact elements while maintaining ease of operation.
4Power
If larger contact elements are mounted to handle increased electrical power, then current capacity increases, but the connector structure becomes more complex and requires larger passages
Solution Approach 1:
The patent utilizes the rotational dimension to achieve locking and unlocking functionality. By designing the cam groove with a 90-degree arc and using a detent ball that moves radially during rotation, the system achieves secure retention without requiring additional axial or lateral space. This dimensional approach allows larger contact elements to be accommodated while maintaining a compact connector structure.
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
This connector (1) for connecting electrical conductors comprises two mating parts (2, 3), male and female respectively, each comprising a connector body made of insulating material having a passage (10) in which a contact is mounted, comprising an insulating contact body and a contact element (8, 9), respectively a pin and a socket. The contact body and the connector body include rotationally locking assembly means (15, 16).