Threaded Conductor Connection Assembly for Low-Resistance HV Joints
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High-voltage electrical connections in vehicles face challenges in achieving a mechanically stable and low-contact-resistance connection between electrical conductors, as direct screw connections can lead to fatigue and damage, while press fits may cause microcracks and increased resistance, and existing non-positive connections require multiple components, increasing assembly effort and costs.
Innovation Solution
A connection arrangement using two fastening elements forming a common primary threaded connection to securely and electrically connect electrical conductors without a press fit, allowing for low contact resistance and reduced assembly effort, with the fastening elements being captively connected to the conductors to avoid surface damage during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a direct screw connection is used between two electrical conductors, then the electrical connection is simple to implement, but the mechanical stability deteriorates due to fatigue and relaxation of copper or aluminum materials
Solution Approach 1:
The connection system is divided into three distinct components: a first fastening element connected to the first electrical conductor, a second fastening element connected to the second electrical conductor, and a connection element joining the two fastening elements. This segmentation allows each component to perform its specific function optimally - the fastening elements provide mechanical strength and fatigue resistance, while the connection element establishes the electrical connection, thereby resolving the contradiction between ease of connection and mechanical stability.
Solution Approach 2:
The connection element acts as an intermediary component between the two electrical conductors. Instead of directly screwing the conductors together, the fastening elements serve as intermediaries that transfer and distribute the mechanical loads, preventing direct stress concentration on the conductor contact surfaces. This intermediary approach maintains mechanical stability while preserving electrical conductivity.
2Stability of the object's composition
If a press fit connection is used between two electrical conductors, then the mechanical stability is improved, but the contact surfaces may be damaged causing microcracks and increased contact resistance
Solution Approach 1:
The fastening elements serve as intermediary components that apply clamping force indirectly to the electrical conductors. Instead of direct press fitting that concentrates stress on the contact surfaces, the fastening elements distribute the mechanical load through their structure, preventing microcrack formation on the conductor surfaces while still achieving secure mechanical connection and maintaining electrical reliability.
Solution Approach 2:
The connection system applies different types of connections at different locations: the fastening elements provide mechanical clamping force at the ends of the conductors, while the contact surfaces maintain direct electrical contact without mechanical stress. This local differentiation of connection types ensures both mechanical stability and electrical reliability by preventing stress concentration at the critical contact interfaces.
3Stability of the object's composition
If mechanical force-lock connections with screw and clamp elements are used, then the mechanical stability is improved, but the device complexity and assembly effort increase due to multiple individual components
Solution Approach 1:
The invention merges the functions of multiple traditional components (screws, clamps, washers, and conductor connectors) into an integrated connection system where fastening elements and connection elements work together as a unified assembly. This merging reduces the total number of individual components required while maintaining mechanical stability, as the fastening elements combine clamping and structural functions, and the connection element simultaneously provides both mechanical joining and electrical connection.
Solution Approach 2:
The fastening elements are designed with multi-functionality, serving both as mechanical fasteners providing clamping force and as structural components that transmit loads between conductors. The connection element similarly provides both mechanical joining and electrical conduction functions. This multi-functionality reduces the need for separate specialized components, thereby simplifying the overall device complexity while maintaining mechanical stability.
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 robust, long-lasting, and low-resistance connection with reduced assembly complexity and costs, ensuring mechanical stability independent of electrical properties, using materials with higher mechanical strength for the fastening elements.
Implementation Method 1
The first fastening element and the second fastening element form a common primary threaded connection in order to connect the first electrical conductor in a force-fitting and electrical manner to the second electrical conductor in a screwed-together state
Implementation Method 2
the first fastening element has a support surface with which it can be supported on a side of the first electrical conductor facing away from the second electrical conductor
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a connection arrangement (4) for connecting a first electrical conductor (2) to a second electrical conductor (3), comprising a first fastening element (6) that can be inserted into an opening (9a) of the first electrical conductor (2) and that has a support surface (11a) with which it can be supported on a side of the first electrical conductor (2) facing away from the second electrical conductor (3), and a second fastening element (7) that has a support surface (11b) with which it can be supported on a side of the second electrical conductor (3) facing away from the first electrical conductor (2). The first fastening element (6) and the second fastening element (7) form a common primary threaded connection (18) in order to connect the first electrical conductor (2) to the second electrical conductor (3) in a force-fit and electrical manner when screwed together.It is provided that the first fastening element (6) has a mechanical connection interface (13) for a captive connection with the first electrical conductor (2).