Conductive Spring Electrical Connection for Vibration Resistance
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Solution Overview
Problem
Existing electrical connection structures in vehicles face challenges in ensuring reliable and vibration-resistant connections between conductive components, particularly in environments where vibration is prevalent, and there is a need for a solution that can maintain contact while allowing for design flexibility and space efficiency.
Innovation Solution
The use of a conductive spring member with multiple contact points, pressed between flat surfaces of bus bars and terminal blocks, ensures secure electrical connections by distributing stress and maintaining contact even under vibration, while allowing for a more compact design by eliminating the need for lengthy insertion types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional insertion-type electrical connection structures are used, then connection reliability may be maintained, but the device occupies more space and lacks design flexibility
Solution Approach 1:
The patent employs a spring member that can elastically deform to maintain contact pressure between conductive parts. The spring member dynamically adapts to dimensional changes and vibration, ensuring reliable electrical connection while occupying minimal space. The elastic deformation capability allows the connection structure to accommodate thermal expansion and mechanical stress without compromising reliability.
Solution Approach 2:
The patent changes the physical state of the connection from rigid insertion to elastic contact. By utilizing the elastic properties of the spring member, the system achieves both compact dimensions and reliable connection. The spring constant and contact pressure can be adjusted to optimize both space utilization and connection reliability for different application requirements.
2Reliability
If rigid electrical connection structures are used, then manufacturing is simpler, but the connection is sensitive to vibration and dimensional changes
Solution Approach 1:
The spring member provides dynamic vibration resistance through elastic deformation. When vibration occurs, the spring member absorbs mechanical shocks and maintains continuous contact between conductive parts. This dynamic response capability significantly improves vibration resistance compared to rigid connections, while the simple spring structure adds minimal complexity to the overall design.
Solution Approach 2:
The spring member acts as a pre-compressed cushioning element that anticipates and absorbs mechanical stresses before they can compromise the electrical connection. The pre-loaded spring provides a buffer against vibration and dimensional changes, protecting the electrical contact from damage without requiring complex protective structures.
3Reliability
If multiple contact points are implemented, then electrical connection reliability improves, but manufacturing precision requirements increase
Solution Approach 1:
The spring member distributes contact pressure across multiple localized contact points along its length. Each contact point provides independent electrical connection, and the spring's elastic properties ensure that pressure is evenly distributed across all contact points. This local quality approach improves reliability through multiple contact paths while the spring's tolerance to misalignment reduces manufacturing precision requirements.
Solution Approach 2:
The patent transforms the contact interface from a single-point rigid contact to a distributed elastic contact. The spring member's elastic modulus and geometry can be optimized to achieve the desired contact pressure distribution. This parameter optimization allows multiple contact points to be effectively utilized while maintaining reasonable manufacturing tolerances for alignment.
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 enhances the reliability and durability of electrical connections by maintaining contact through multiple points, improving resistance to vibration and allowing for a more compact and flexible design compared to traditional insertion types.
Implementation Method 1
The conductive spring is pressed by the first plate and the second plate so as to be pressed by the first plate and the second plate. The conductive spring includes a plurality of first contact points contacting with the first plate and a plurality of second contact points contacting with the second plate.
Data Source
AI summary
An electrical connection structure includes a first conductor, a second conductor, and a conductive spring. The first conductor includes a first plate. The second conductor includes a second plate opposite to the first plate. The conductive spring is provided between the first plate and the second plate so as to be pressed by the first plate and the second plate. The conductive spring includes a plurality of first contact points contacting with the first plate and a plurality of second contact points contacting with the second plate.