Power Connector Contact With Segmented Legs For Reduced Resistance
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Solution Overview
Problem
Electrical connectors designed for high current and power transmission face challenges in managing heat buildup due to contact resistance, mechanical stability, and manufacturing costs, while maintaining efficiency and longevity.
Innovation Solution
A power connector contact with a crimping section and a shaft section featuring two legs, allowing for efficient material usage and manufacturing, reduced resistance, and modular design for adaptable orientations, which can be soldered or ultrasonically welded for enhanced robustness and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the contact size is reduced to achieve compact connector design, then the connector size and packing density are improved, but the contact resistance increases causing higher temperatures
Solution Approach 1:
The contact is divided into multiple legs (at least two legs) that are arranged parallel to each other. This segmentation allows the electrical current to be distributed across multiple parallel conductive paths, effectively reducing the overall contact resistance while maintaining a compact connector form factor. The segmented leg structure provides increased conductive cross-section without proportionally increasing the overall connector volume.
Solution Approach 2:
The contact legs are arranged in a parallel configuration extending in multiple directions from the crimping section. This spatial arrangement in multiple dimensions increases the effective conductive area without proportionally increasing the connector's external dimensions, allowing reduced resistance while maintaining compact size.
2Temperature
If more conductive material is added to reduce contact resistance, then the temperature and resistance are improved, but the manufacturing cost and material usage increase
Solution Approach 1:
Instead of adding a single large mass of conductive material, the solution segments the material into multiple thin legs. This segmentation achieves the same or better resistance reduction effect while using less total material, as the parallel arrangement provides increased effective cross-section without proportional material increase.
Solution Approach 2:
The conductive material is arranged in a multi-dimensional parallel leg configuration rather than a single thick element. This spatial arrangement maximizes the conductive cross-section per unit volume of material, achieving low resistance with minimal material consumption.
3Ease of manufacture
If the contact is made as a single integrated piece to simplify manufacturing, then the manufacturing process is simplified, but the adaptability to different orientations and applications is reduced
Solution Approach 1:
The contact is segmented into modular components: a crimping section and multiple legs. This segmentation allows the legs to be arranged in different orientations and configurations while maintaining a standardized crimping interface, providing design flexibility without complicating the fundamental manufacturing process.
Solution Approach 2:
The standardized crimping section serves as a universal interface that can accommodate various leg configurations and orientations. This multi-functional design allows the same basic contact structure to be adapted for different applications and mounting orientations while maintaining manufacturing efficiency.
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 effectively reduces heat generation, enhances mechanical stability, and allows for cost-efficient manufacturing while maintaining high current and power transmission capabilities, preventing contact pull-out and facilitating efficient assembly.
Implementation Method 1
The crimping section is adapted to receive an end of an electrical conductor and for being crimped onto the conductor
Implementation Method 2
The shaft section including two legs provides relatively much conductive material between the crimping end and the mating end, thus providing a relatively low resistance of the contact
Implementation Method 3
The first member and a second member which are mounted to each other, such as by a soldered connection or ultra sonic welding
Implementation Method 4
The first member and a second member which are mounted to each other, such as by a soldered connection or ultra sonic welding
Implementation Method 5
Arranging a portion of the legs with a separation between the legs may increase heat exchange to surrounding air for increased cooling of the contact
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
The present invention relates to contact, comprising a mating end for mating to two or more contacts and a conductive section. The conductive section includes a crimping end which is adapted to receive an electrical conductor and for being crimped thereto and a shaft section which extends between the crimping end and the mating end and includes two legs.