Receiving Unit for Circuit Carrier with Oblique Insertion
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Solution Overview
Problem
Existing connection methods for circuit carriers in hybrid drives, such as soldering, welding, screw contacts, and pressure contacts, face issues with poor detachability, high assembly costs, sensitivity to contact forces, and oxidation, limiting their effectiveness for high current loads and reliability.
Innovation Solution
A receiving unit with a guide rail and spring contacts that allow oblique insertion, scratching off oxide layers, and mechanical contacts to absorb bending forces, enabling stress-free mounting and reliable connections with reduced handling forces and assembly errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering, welding or screw contacts are used to connect the circuit carrier, then reliable electrical connection is achieved, but assembly costs increase and assembly errors become more frequent
Solution Approach 1:
The patent replaces traditional mechanical connection methods (soldering, welding, screw contacts) with a press-fit mechanical insertion system. The circuit carrier is inserted into a receiving unit with guide rails and positioning elements that automatically align and secure the carrier without requiring complex assembly processes, thereby reducing assembly costs and errors while maintaining reliable electrical connection through direct contact between contact elements and conductor tracks.
2Reliability
If plug contacts are used for high current loads, then electrical connection is achieved, but space requirement increases and plugging forces become excessively high
Solution Approach 1:
The patent applies local quality by designing different contact elements with optimized properties for their specific functions. The receiving unit includes guide rails for alignment, positioning elements for precise location, and contact elements sized and positioned according to the current load requirements of individual connections. This allows compact arrangement of high-current contacts where space is critical, while still providing adequate contact area and force distribution.
3Adaptability or versatility
If connector systems with flaps and locks are used, then detachable connection is achieved, but bending stresses proportional to contact force are transmitted to the circuit carrier
Solution Approach 1:
The patent extracts the stress-absorbing function from the circuit carrier by introducing separate structural elements in the receiving unit. Guide rails and positioning elements absorb the insertion and contact forces, preventing these forces from being transmitted to the circuit carrier. The circuit carrier itself is designed without integrated locking mechanisms, separating the connection function from the carrier structure and eliminating bending stress transmission.
4Reliability
If pressure contact systems are used to ensure adhesion, then electrical connection is achieved, but space requirement increases and assembly errors occur
Solution Approach 1:
The patent implements self-service through the press-fit insertion system where the circuit carrier automatically aligns with guide rails and positions itself using positioning elements during insertion. The contact elements are designed to make automatic electrical contact without requiring external adjustment or complex assembly procedures, ensuring reliable adhesion through the mechanical press-fit connection itself while minimizing space requirements through compact arrangement of essential components.
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 reliable, efficient, and cost-effective connection system for circuit carriers with high current loads, ensuring low material costs, reduced assembly effort, and high reliability while minimizing stress on the circuit carrier.
Implementation Method 1
the at least one contact is a spring contact
Implementation Method 2
an oxide layer can be scratched by means of the electrical contact when it is inserted into the receiving unit, thus ensuring electrical contact
Data Source
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AI summary
The invention relates to a receiving unit for a circuit carrier, wherein the receiving unit comprises at least one electric contact, wherein the circuit carrier can be inserted obliquely to an end position of the circuit carrier into the receiving unit, and wherein the receiving unit is designed such that, in an inserted state of the circuit carrier, substantially no bending forces act via the at least one electric contact upon the circuit carrier. The invention further relates to a connection system and to an electric machine having a receiving unit of said kind and to a motor vehicle having a corresponding electric machine.