Terminal Contact Assembly for Low-Resistance High-Current Connection
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Solution Overview
Problem
Conventional terminal units experience high electrical resistance and heat generation when dealing with large electric currents due to the interposition of the second terminal between the first terminal and the electric wire end, leading to unsuitable performance for high-current applications.
Innovation Solution
The first terminal is designed with projection contacts that directly contact the electric wire end through through holes in the second terminal, eliminating the additional resistance contributed by the second terminal and allowing for direct electrical conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the second terminal is interposed between the first terminal and the electric wire end, then the terminal unit can be assembled with standard connection structures, but the electrical resistance becomes large due to contact resistance and conductor resistance
Solution Approach 1:
The invention extracts the second terminal from the electrical conduction path. The projection contact of the first terminal directly contacts the electric wire end through the through hole of the second terminal, bypassing the second terminal's conductor resistance while maintaining its structural role in the assembly
Solution Approach 2:
The through hole of the second terminal serves as an intermediary structure that allows the projection contact to pass through and establish direct contact with the electric wire end, while the second terminal itself remains in place to provide mechanical support and positioning
2Device complexity
If the second terminal is interposed between the first terminal and the electric wire end, then the assembly structure can be simplified, but heat is generated upon applying large electric current
Solution Approach 1:
The second terminal is extracted from the electrical conduction path by allowing the projection contact to pass through it and directly contact the electric wire end, eliminating the source of resistive heat generation while keeping the assembly structure intact
3Loss of energy
If the projection contact directly contacts the electric wire end, then the electrical resistance is reduced, but the second terminal must have through holes for visual observation
Solution Approach 1:
The through hole of the second terminal serves multiple functions: it allows the projection contact to pass through for direct electrical contact, provides visual observation of the electric wire end for assembly verification, and maintains the structural integrity of the second terminal
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 configuration reduces overall electrical resistance and minimizes heat generation, enabling the terminal unit to handle large electric currents effectively.
Implementation Method 1
a pressing member which presses the first terminal and the second terminal against each other for contact
Data Source
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AI summary
To provide a terminal unit in which electric resistance is small and heat generation is little even if large electric current is applied. A terminal unit 10 comprises: a first terminal 11; a second terminal 21 which is assembled in and connected with the first terminal 11, the second terminal 21 being connected with an electric wire end 42a; and a pressing member 31 which presses the first terminal 11 and the second terminal 21 against each other for contact, wherein the first terminal 11 has one or more projection contacts 13 projecting in a direction orthogonal to a first terminal side assembly surface 12 in which the second terminal 21 is to be assembled, the second terminal 21 has one or more through holes 24 through which the electric wire end 42a can be visually observed from a second terminal side assembly surface 22 in which the first terminal 11 is to be assembled, and in a state where the first terminal 11 and the second terminal 21 are assembled, and are pressed by the pressing member 31 and brought into contact, the projection contacts 13 of the first terminal 11 go through the through holes 24 of the second terminal 21 and directly contact the electric wire end 42a.