Temperature-Responsive Claw Pin for Stable High-Current Contact Force
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing high-current contact solutions face challenges with temperature-induced loss of contact normal force, requiring high assembly forces and being prone to assembly errors, while incorporating complex and costly components that are difficult to assemble.
Innovation Solution
A contact plug design featuring claw-like elements made of multilayer metal or shape-memory alloy, with varying widths and radii, that deform geometrically in response to temperature changes to maintain or increase contact normal force, reducing assembly forces and enhancing stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spring steel materials are used to generate high normal contact forces, then contact reliability is improved, but assembly forces become excessively high making assembly difficult
Solution Approach 1:
The patent uses temperature-dependent parameter changes in the contact socket material (thermal expansion coefficient differences) to automatically adjust the contact normal force. At operating temperature, the material expands to increase contact force, while at assembly temperature, the contact force remains low, eliminating the need for high assembly forces while maintaining reliable contact under load.
Solution Approach 2:
The contact socket is designed to self-adjust its contact normal force based on temperature changes during operation. The material properties cause automatic expansion and contraction that increases contact force when heated by current flow, maintaining reliable electrical contact without requiring external adjustment mechanisms or high assembly forces.
2Reliability
If complex components with temperature-dependent deformation are incorporated, then contact normal force stability is improved, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent merges the temperature-dependent deformation function directly into the contact socket structure itself, eliminating the need for separate bimetallic strips or additional deformation components. The contact socket material is designed with specific thermal expansion properties that cause it to deform and increase contact force automatically, simplifying the overall device while maintaining stability.
Solution Approach 2:
The contact socket utilizes inherent material parameter changes (thermal expansion coefficient) to achieve temperature-dependent deformation. This eliminates complex mechanical deformation mechanisms while maintaining contact normal force stability, as the material naturally expands when heated by electrical current, increasing contact pressure automatically.
3Reliability
If copper materials are used for contact elements, then electrical conductivity is improved, but spring force is lost at elevated temperatures
Solution Approach 1:
The patent employs composite material structures where copper contact elements are combined with materials exhibiting positive thermal expansion properties. The copper provides excellent electrical conductivity, while the composite structure or accompanying materials expand when heated, compensating for copper's loss of spring force at elevated temperatures and maintaining reliable contact pressure.
Solution Approach 2:
The patent compensates for copper's temperature-dependent spring force loss by utilizing parameter changes in the contact socket material or surrounding structure. As temperature increases, the socket material expands or deforms to increase contact normal force, offsetting the softening of copper and maintaining both electrical conductivity and mechanical contact force.
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 design ensures low assembly forces at room temperature and increased contact normal force at elevated temperatures, improving connector reliability and ease of assembly, while maintaining high pull-out forces and reducing electrical resistance.
Implementation Method 1
claw-like elements made of multilayer metal or shape-memory alloy, with varying widths and radii, that deform geometrically in response to temperature changes
Implementation Method 2
claw-like elements made of multilayer metal or shape-memory alloy
Implementation Method 3
reliable electrical contact between the connectors is crucial... contact force – more precisely, the normal contact force – is as high as possible and remains constant to press the contact partners firmly together
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a contact plug for transmitting electrical energy by means of detachable contact with a contact socket, wherein the contact plug is designed as a claw pin, in that it has at least one claw-shaped element which deforms through temperature changes and realizes a change in the contact normal force between the claw pin and the contact socket.