Beveled Contact Arrangement for High-Current Conductor Track Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing resistance structures for electrical heating devices face challenges in reliably connecting lead wires to conductor tracks, particularly when high currents are involved, as conventional methods like soldering, welding, or pressing are inefficient.
Innovation Solution
A contact arrangement with a beveled flat contact element and a connecting element, surrounded by a plastic housing, allows for easy and reliable connection to a base plate, enabling a conductive layer to be applied and connected in a single operation using cold gas spraying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connection methods (soldering, welding, pressing) are used to connect lead wires to conductor tracks, then electrical connection is achieved, but the connection reliability is insufficient particularly for high current applications
Solution Approach 1:
The patent replaces conventional mechanical/electrical connection methods (soldering, welding, pressing) with a cold gas spraying process that creates a metallurgical bond between the conductive layer and the contact element. This substitution achieves reliable high-current connections without the complexity and reliability issues of traditional methods.
Solution Approach 2:
The patent changes the physical state and properties of materials through cold gas spraying, creating a conductive layer with optimized electrical and mechanical properties. The beveled geometry of the contact element also changes the distribution of electrical current and mechanical stress, improving connection reliability for high current applications.
2Reliability
If a conductive layer is applied to connect to the contact element, then electrical connection is established, but the process requires multiple operations and steps
Solution Approach 1:
The patent combines the contact element geometry design with the conductive layer application process. The beveled shape of the contact element is specifically designed to work with the cold gas spraying process, allowing the conductive layer to be applied in a single operation that achieves both mechanical support and electrical connection, eliminating multiple separate steps.
Solution Approach 2:
The contact element is pre-formed with a specific beveled geometry before the conductive layer is applied. This preliminary shaping creates optimal surfaces and geometries that enable the subsequent cold gas spraying process to achieve reliable electrical connection in a single step, rather than requiring multiple operations to create the necessary connection geometry.
3Ease of manufacture
If the contact element has uniform thickness, then manufacturing is simple, but the conductive layer must span edges which complicates the connection process
Solution Approach 1:
The patent introduces asymmetry in the contact element thickness, creating a beveled shape that is thinner at the edges and thicker at the center. This asymmetric geometry eliminates the need for the conductive layer to span edges, simplifying the application process while maintaining manufacturing feasibility through standard machining or molding techniques.
Solution Approach 2:
The contact element has different thicknesses in different regions: thicker at the center for mechanical strength and electrical connection, and thinner at the edges to eliminate the need for the conductive layer to bridge edge gaps. This local variation in quality optimizes both the mechanical and electrical properties while simplifying the overall connection process.
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 solution facilitates a robust and efficient connection of conductor tracks to base plates, ensuring reliable electrical and mechanical contact, even with high currents, while simplifying the production and installation process.
Implementation Method 1
The conductive layer can be applied for example by means of cold gas spraying
Data Source
AI summary
A contact arrangement with a flat contact element with an upper side and an underside, the thickness of which decreases toward three of its edges from the upper side to the underside, and with a connecting element, which is electrically and mechanically connected to the contact element and is further away from the underside of the contact element than from its upper side. Also disclosed is a device with a base plate and a contact arrangement arranged thereon and a conductor track, which is formed on the contact element and a region of the base plate.