Active Electrical Component with Elastic Plug Contacts
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Solution Overview
Problem
Existing switching elements, such as relays and contactors, face reliability issues due to unintentional disconnection with plug-type contacts and high production complexity and costs associated with soldering, especially when handling high currents.
Innovation Solution
An active electrical component with plug-type or pressing contacts and a force transmission structure composed of chains of rigid members that transmit forces from the component's side opposite the contacts, allowing for reliable high-current connections without mechanically loading other components, using a housing made from thermoplastic materials for cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If plug-type contacts are used for connection, then ease of insertion and separation is improved, but reliability deteriorates due to unintentional disconnection
Solution Approach 1:
The contact is designed with elastic properties, allowing it to dynamically adapt during insertion and operation. The elastic contact can deform to engage with the counter-contact and maintain continuous pressure, ensuring reliable connection while remaining easy to insert. This dynamic behavior resolves the contradiction between ease of operation and connection reliability.
2Reliability
If soldering is used to connect contact and counter-contact, then connection reliability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces the thermal soldering process with a mechanical connection system. The elastic contact mechanically engages with the counter-contact through insertion, eliminating the need for soldering equipment and thermal processes. This mechanical substitution maintains connection reliability while significantly reducing manufacturing complexity and cost.
3Reliability
If soldering is used to connect contact and counter-contact, then connection reliability is improved, but production cost increases
Solution Approach 1:
The patent replaces the thermal soldering process with a mechanical connection system. The elastic contact mechanically engages with the counter-contact through insertion, eliminating the need for soldering equipment and thermal processes. This mechanical substitution maintains connection reliability while significantly reducing manufacturing complexity and cost.
4Reliability
If high forces are applied to insert the contact, then connection reliability is improved, but mechanical loading of other components increases
Solution Approach 1:
The patent extracts the force transmission function into a dedicated force transmission structure that is separate from the contact itself. This structure is designed to handle high insertion forces and transmit them to the mounting structure, preventing these forces from being transmitted to other sensitive components like the coil or armature. This separation allows high retention forces while protecting other components from excessive mechanical loading.
Data Source
AI summary
An active electrical component is disclosed. The active electrical component comprises a contact extending away from an outer side of the component in an insertion direction, and a force transmission structure extending to the contact in a continuous manner from a side of the component opposite the contact.