Bent Metallic Strip Connector for High-Current Contact Pressure
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Solution Overview
Problem
Existing electrical connectors with rigid contact elements and mating contact elements suffer from reduced current transmission due to lack of elasticity and contact pressure, leading to inefficiencies in high-current applications, and alternative solutions like toroidal springs are costly.
Innovation Solution
An electrical connecting element with a metallic strip having alternating first and second sections bent to form spring arms, providing elasticity and sufficient contact pressure for improved current transmission, and manufactured using a punching and bending technique for cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid contact elements are used, then structural strength is improved, but current transmission capability deteriorates due to lack of contact pressure and small contact area
Solution Approach 1:
The patent uses a flexible metallic strip with alternating bent sections instead of rigid contact elements. The strip can be elastically deformed to generate contact pressure while maintaining structural integrity, resolving the contradiction between strength and current transmission capability.
Solution Approach 2:
The metallic strip is designed with alternating bent sections that can dynamically adapt to surface variations and generate contact pressure through elastic deformation. This dynamic flexibility enables both structural strength and reliable current transmission.
2Reliability
If elastic contact elements are used to improve current transmission, then contact pressure is improved, but manufacturing cost deteriorates due to complex structures like toroidal springs
Solution Approach 1:
The patent changes the geometric parameters of a simple metallic strip by creating alternating bent sections with different radii. This parameter modification provides elastic contact pressure without requiring complex structures like toroidal springs, thus improving current transmission while maintaining ease of manufacture.
Solution Approach 2:
The metallic strip is segmented into alternating first and second sections with different bending radii. This segmentation creates multiple contact points with distributed pressure, achieving reliable current transmission through a simple, cost-effective structure.
3Reliability
If alternating bent sections are formed in a metallic strip, then current transmission is improved through distributed contact pressure, but device complexity increases
Solution Approach 1:
The alternating bent sections of the metallic strip serve multiple functions simultaneously: they provide structural strength, generate contact pressure, accommodate surface variations, and enable current transmission. This multi-functionality improves current transmission without proportionally increasing device complexity.
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 achieves uniformly distributed high-current transmission with good mechanical and electrical properties, accommodating surface variations, and reduces manufacturing costs through automated production.
Implementation Method 1
each first section is bent about an axis of rotation which runs parallel to the central axis, wherein each first section is bent in such a way as to contact the contact element in each case, and each second section is bent in such a way as to contact the mating contact element in each case
Data Source
Figure 1A~1D
Figure 1E~2A
Figure 2B~2E
AI summary
The present invention relates to an electrical connecting element. The present invention further relates to an electrical connection. Finally, the present invention also relates to a method for producing an electrical connecting element. An electrical connecting element (1) for electrically connecting a contact element (15) to an associated mating contact element (16) has a metallic strip (2) with a central axis M. Along the central axis M, first sections (3) of the metallic strip (2) are formed alternately at a first side end S1 of the metallic strip (2), and second sections (4) of the metallic strip (2) are formed alternately at a second side end S2 of the metallic strip (2). Each first section (3) is connected to the two next adjacent second sections (4) of the metallic strip (2).The first sections (3) and the second sections (4) are each bent about a rotation axis R1, R2, which runs parallel to the center axis M. Each first section (3) is bent in such a way as to contact the contact element (15) in each case, and each second section (4) is bent in such a way as to contact the counter-contact element (16) in each case.