Single-Bolt Connection Body for High-Current Terminal Contact
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Solution Overview
Problem
Conventional connector assemblies face issues with an increased number of components and insufficient contact strength for large currents, particularly in connector assemblies where fitting is achieved by a fastening bolt and conduction is facilitated by a clip spring.
Innovation Solution
A connection body design featuring a first insulating plate with cutout portions, first and second terminals with flat plate shapes, and a second insulating plate with pressing portions, allowing for a single bolt to secure conductive contact between the terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fastening bolt and clip spring configuration is used to achieve fitting and conduction, then the connector assembly can be assembled, but the number of components increases and contact strength becomes insufficient for large currents
Solution Approach 1:
The patent combines the fitting function and conduction function into a single integrated structure. The connection body includes terminals with contact portions that directly contact the second connector, eliminating the need for separate clip springs. The fastening bolt simultaneously secures both the mechanical fitting and establishes electrical conduction through the integrated terminal structure.
Solution Approach 2:
The patent extracts and removes the clip spring component from the connector assembly. By designing terminals with flat plate-shaped contact portions that directly engage with the second connector, the invention eliminates the intermediary clip spring, thereby reducing component count while maintaining or improving contact strength for large current applications.
2Ease of manufacture
If multiple components are used for fitting and conduction, then assembly can be achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The invention merges multiple functions (mechanical support, electrical conduction, and fastening) into fewer integrated components. The connection body with its terminals and contact portions performs both structural and electrical functions, reducing the total component count and simplifying the manufacturing process by eliminating the need to manufacture and assemble separate clip springs.
3Strength
If conventional connector assembly structure is used, then assembly can be completed, but the structure becomes complex and contact strength is insufficient for large currents
Solution Approach 1:
The patent applies local quality by designing the contact portions with specific flat plate shapes that provide enhanced contact area and strength at the critical connection points. The terminals are configured with widths greater than the cutout portions, creating locally reinforced contact regions that can withstand large currents without requiring complex overall structural changes.
Data Source
Figure 1
Figure 2
Figure 3(a)~3(c)
AI summary
A second bolt insertion portion and a third bolt insertion portion have a following positional relationship in a connection body. The positional relationship is a positional relationship which allows fastening by insertion of a single bolt in a state in which base portions of a pair of first terminals are inserted into respective second cutout portions, a pair of second terminals are mounted on respective end portions of first contact portions, and a pair of first pressing portions are mounted on respective end portions of second contact portions. The fastening makes the first contact portions and the respective second contact portions conductive.