Compacted Conductor Contact with Conductive Layer for Low Resistance
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Solution Overview
Problem
Existing electrical conductor assemblies experience high contact resistance due to the compaction of conductor wires, which hinders efficient connection with other elements.
Innovation Solution
A layer of a second electrically conductive material is applied to the contact surface of the compacted contact unit, and a stabilization sleeve and guide member are integrated to enhance stability and facilitate attachment, while a touch guard provides insulation and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conductor wires are compacted to form a contact unit, then connection simplicity is improved, but contact resistance increases
Solution Approach 1:
The patent applies a conductive material layer with superior electrical properties specifically at the contact surface of the contact unit, while the bulk conductor wires maintain their compacted structure for mechanical stability. This local enhancement of electrical conductivity at the critical contact interface resolves the contradiction between compacted connection simplicity and acceptable contact resistance.
Solution Approach 2:
The contact unit comprises a composite structure combining compacted conductor wires (providing mechanical integrity and ease of connection) with a conductive material layer (providing low contact resistance). This composite approach allows simultaneous achievement of simple connection and low contact resistance by combining materials with complementary properties.
2Reliability
If a conductive material layer is added to the contact surface, then contact resistance is reduced, but device complexity increases
Solution Approach 1:
The conductive material layer is applied to the contact surface during the manufacturing process before final assembly, integrating the low-resistance feature into the production flow. This preliminary action incorporates the complexity into manufacturing rather than requiring additional assembly steps, thereby minimizing the impact on overall device complexity while achieving reduced contact resistance.
Data Source
AI summary
An electrical conductor assembly includes a line section having a plurality of conductor wires formed of a first electrically conductive material, a contact section in which the conductor wires are compacted to form a contact unit, and a layer formed of a second electrically conductive material. The layer is disposed on a contact surface of the contact unit.