Undulated Electrical Connector for High Current

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Solution Overview

Problem

Existing electrical connectors face issues with current carrying capacity, mechanical holding power, and reusability due to small cross-sectional pins and deformation during installation, leading to inefficiencies and increased costs for maintenance and replacement.

Innovation Solution

An electrical connection device featuring an undulated projection with multiple adjacent wave shapes that creates a secure, press-fit connection with a slot on a PCB or bus bar, providing increased copper mass and resilient spring forces for reliable high-amperage transmission, and allowing for multiple insertions without deformation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If small cross-sectional pins are used to connect contacts to the board, then the device complexity is reduced, but the current carrying capacity is limited

Engineering Contradiction:

Improvecurrent carrying capacityVSAvoidconnector structure

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The invention transitions from a single-point pin connection to a distributed surface contact system. The undulated projection creates multiple contact points across the slot surface, effectively moving from a zero-dimensional point contact to a two-dimensional surface contact, thereby increasing current carrying capacity without proportionally increasing device complexity

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The undulated projection is segmented into multiple wave shapes, each creating individual contact points with the slot. This segmentation distributes the electrical current across multiple parallel pathways, increasing overall current carrying capacity while maintaining a relatively simple single-piece connector structure

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If compliant tails are used for solderless electrical connection, then ease of manufacture is improved, but reusability deteriorates due to deformation of the hole

Engineering Contradiction:

Improveintegration of electrical componentsVSAvoidreusability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Instead of deforming the hole in the board to create retention (as in prior art), the invention inverts the approach by having the projection deform elastically during insertion and then spring back to create continuous contact pressure. The board hole remains undeformed, enabling reuse while maintaining electrical connection

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The undulated projection introduces dynamic elasticity to the connection system. The spring-like undulations allow the connector to accommodate thermal expansion, vibration, and assembly tolerances while maintaining reliable electrical contact, thereby improving both reusability and connection reliability

Inventive Principle:

Principle #15Dynamics

3Reliability

If soldering is used for electrical connection, then reliability is improved, but temperature requirements cause damage to the board

Engineering Contradiction:

Improveelectrical connectionVSAvoidsoldering temperature

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The invention replaces the thermal field (soldering) with a mechanical field (elastic deformation and spring force). The undulated projection uses mechanical spring pressure to create reliable electrical contact, eliminating the need for high-temperature soldering that can damage the PCB while maintaining connection reliability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Quantity of substance

If the projection width is increased to carry more current, then current carrying capacity is improved, but the slot width must also increase

Engineering Contradiction:

Improvecopper massVSAvoidslot width

Core Design Contradiction:

Quantity of substanceVSArea of stationary object

Solution Approach 1:

The invention utilizes the third dimension (depth/height) by creating undulations in the projection. This allows the connector to maintain a compact slot width while increasing effective copper mass through the vertical undulated structure, effectively trading vertical space for horizontal space efficiency

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 undulated design enhances current carrying capacity, maintains mechanical integrity against shock and vibration, and supports reusability by ensuring continuous electrical contact without damaging the PCB, thus reducing maintenance costs and improving system reliability.

Implementation Method 1

The spring force generated by the flexing undulated shape of the projection forms secure electrical continuity between the undulated contact and the board

Methodology Applied

Scientific EffectSpring force: Spring

Implementation Method 2

The undulated projection is press fit into the slot thereby creating a retention force

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS10553976B1Electrical connection device

Publication Date: 2020.02.04 THEIN ROBERT HLA

AI summary

An electrical connection device includes a female connector which has a slot. A male connector has an undulated projection which is insertable into the slot. The slot has a slot width, and the undulated projection has a projection width which is greater than the slot width. The electrical connection device is capable of carrying more current that existing solder and compliant tail connections. In a second embodiment an undulated sleeve is applied to a circular connector.