Wire-wound charger, rotating electrical connection structure thereof, and formation method thereof
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Solution Overview
Problem
Charging devices with wire-wound mechanisms face issues of copper foil wear and electrical connection failure due to high friction, requiring improved reliability and positioning accuracy in the rotating electrical connection structure.
Innovation Solution
A rotating electrical connection structure using conductive elastic sheets and conductive rings with integrated indentations, replacing micron-level copper foil with thicker conductive sheets for reduced wear and enhanced alignment, facilitated by a stamping process for mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If micron-level copper foil is used for electrical connection, then the device structure is simple, but the copper foil is easy to wear and has short working period
Solution Approach 1:
The patent changes the thickness parameter of the conductive material from micron-level copper foil to millimeter-level thick copper sheet (0.1-1.0mm), fundamentally altering the wear resistance and mechanical strength characteristics while maintaining electrical conductivity function
Solution Approach 2:
The patent creates a composite structure combining thick copper sheet with elastic sheet material, forming a composite conductive elastic sheet that integrates both electrical conductivity and elastic deformation capabilities, solving the contradiction between structural simplicity and reliability
2Device complexity
If copper foil is used for electrical connection, then the device structure is simple, but the working period is short due to wear
Solution Approach 1:
The patent increases the thickness parameter from microns to millimeters (0.1-1.0mm), which directly extends the working period by providing sufficient material thickness to withstand repeated friction and deformation cycles without wearing through
Solution Approach 2:
The patent introduces elastic deformation capability to the conductive sheet, allowing it to dynamically adapt to rotational movements and friction forces, thereby extending the working period through reversible deformation rather than permanent wear
3Reliability
If high positioning accuracy is required for electrical connection, then the connection reliability is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent segments the positioning function from the connection function by introducing separate positioning structures (positioning holes and positioning ribs) that are integrally formed with the conductive sheet, allowing independent optimization of positioning accuracy without complicating the overall connection structure
Solution Approach 2:
The patent merges the positioning ribs with the conductive sheet into an integrally formed structure, eliminating separate positioning components and simplifying manufacturing while maintaining high positioning accuracy through the unified structure
4Device complexity
If traditional copper foil is used, then the device structure is simple, but the service life is short
Solution Approach 1:
The patent fundamentally changes the thickness parameter from micron-level to millimeter-level (0.1-1.0mm), providing sufficient material reserve to withstand long-term friction and deformation, thereby extending service life from months to years
Solution Approach 2:
The patent designs the thick conductive sheet with sufficient thickness margin to beforehand cushion against wear and deformation during the product lifecycle, ensuring reliable electrical connection throughout the intended service life
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 solution provides a durable and reliable electrical connection with increased service life and improved production efficiency through high alignment accuracy and stamping technology utilization.
Implementation Method 1
a plurality of annular elastic sheets... each annular elastic sheet abuts against and is electrically connected to a corresponding conductive ring
Data Source
AI summary
The present invention relates to a wire-wound charger and a rotating electrical connection structure and a formation method thereof. The rotating electrical connection structure comprises two circuit boards, a conductive elastic sheet group and a conductive sheet assembly. The group and the assembly are mounted on one circuit board. The conductive elastic sheet group comprises a plurality of annular elastic sheets, and the conductive sheet assembly comprises a plurality of conductive rings, a plurality of first and second indentation portions are formed between adjacent sheets or adjacent rings, respectively. The circuit boards are respectively provided with hole portions corresponding to the indentation portions. The sheet or ring have a predetermined thickness and is wear resistance, thus providing a long working period. Further, the structure has a high positioning accuracy, is reliable and readily to be formed.