Stacked Sheet Terminal Electrical Connector for High Current Bus Bars
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Solution Overview
Problem
Existing electrical connectors with upper and lower conductive terminals face high contact resistance and insufficient clamping force when connecting bus bars carrying large currents, due to limited electrical contacts and clamping force provided by curved cantilevers.
Innovation Solution
The electrical connector features a plurality of sheet terminals with main bodies and cantilevers that are assembled in a stacked manner, forming a receiving chamber with increased contact points and clamping force, reducing contact resistance and enhancing clamping efficiency by using multiple contact portions and elastic cantilevers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If curved cantilevers are used to clamp the bus bar, then the connector can provide clamping force, but the contact resistance is relatively large due to fewer electrical contacts
Solution Approach 1:
The connector is divided into multiple sheet terminals stacked together, with each sheet terminal providing multiple contact portions. This segmentation increases the total number of electrical contacts from 24 to 48 or more, thereby reducing contact resistance while maintaining manageable structural complexity through modular design
Solution Approach 2:
The patent transitions from a single-layer curved cantilever structure to a multi-layer stacked structure. By adding the vertical dimension with multiple sheet terminals stacked together, the number of electrical contacts increases significantly without proportionally increasing horizontal space requirements, effectively reducing contact resistance
2Force
If a single piece extension conductive component is used for each conductive terminal, then the structure is simple, but the clamping force is insufficient for large current transmission
Solution Approach 1:
Multiple sheet terminals are stacked and combined together to form a unified connector assembly. The clamping forces from individual sheet terminals accumulate, providing sufficient total clamping force for large current transmission while maintaining the simplicity of each individual sheet terminal component
Solution Approach 2:
The connector is segmented into multiple sheet terminals, each providing a portion of the total clamping force. This segmentation allows the system to achieve high total clamping force through the cumulative effect of multiple simpler components rather than requiring a single complex high-force component
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
This design significantly reduces contact resistance and increases clamping force, enabling reliable electrical connections for bus bars carrying high currents, such as 100 A direct current or 45 A alternating current, while maintaining a compact structure.
Implementation Method 1
at least a pair of elastic cantilevers (22, 23, 24, 25) extending from at least one of a first side and an opposite second side of the main body (21)
Data Source
AI summary
An electrical connector includes a plurality of sheet terminals each having a main body and at least a pair of cantilevers. Each pair of the cantilevers extends from at least one of a first side and an opposite second side of the main body and has a pair of contact portions protruding toward each other inside a pair of free ends of the pair of cantilevers. The plurality of sheet terminals are assembled together in a stacked manner and a receiving chamber with an insertion opening is formed between the pair of cantilevers of the plurality of sheet terminals.