Conductor Connection Press Fit Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing conductor connections, particularly in inductive components, face challenges with mechanical stability and efficiency due to insufficient mechanical attachment methods, which are often time-consuming and costly.
Innovation Solution
A conductor connection utilizing a metal strip piece bent around conductors to create a press connection, known as a 'splice crimp,' with a shape that adapts to the conductors to reduce mechanical and thermomechanical stress, allowing for improved stability without additional fastening technologies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If additional mechanical attachment methods are used to improve mechanical stability, then the mechanical stability is improved, but the production time and cost increase
Solution Approach 1:
The patent combines the mechanical fastening function and the electrical connection function into a single integrated connector body. The connector simultaneously secures multiple conductors mechanically while providing electrical pathways, eliminating the need for separate mechanical attachment steps and subsequent soldering or welding operations.
Solution Approach 2:
The connector is designed as a multi-functional component that performs multiple tasks: mechanical retention of conductors, electrical connection between conductors, and structural support. This universal design allows a single component to replace what would traditionally require multiple separate components and assembly steps.
2Ease of manufacture
If conventional winding fastening is used to connect conductors, then the assembly is simple, but the mechanical stability is insufficient for subsequent electrical connection
Solution Approach 1:
The connector is divided into distinct functional zones: opening areas for conductor insertion, pressing areas for mechanical securing, and connection areas for electrical contact. This segmentation allows each zone to be optimized for its specific function while maintaining overall simplicity in the manufacturing process.
Solution Approach 2:
The connector is pre-formed with the appropriate geometry and structural features during manufacturing, including pre-positioned pressing surfaces and connection contact areas. This preliminary preparation eliminates the need for complex assembly operations, as the connector is ready to secure and electrically connect conductors in a single operation.
3Strength
If a rigid connector shape is used, then the structural strength is high, but the mechanical and thermomechanical stress on conductors increases
Solution Approach 1:
The connector features locally optimized geometries in different areas: the opening areas have adapted contours that match the conductor paths to minimize stress concentration, while other areas maintain rigid structures for overall strength. This local quality variation allows the connector to be both strong and gentle on conductors where needed.
Solution Approach 2:
The opening areas of the connector incorporate curved and rounded contours that follow the natural path of the conductors, avoiding sharp angles and rigid edges. This curvature design reduces stress concentration points and prevents mechanical damage to conductors during insertion and under thermal cycling conditions.
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 enhanced mechanical stability and reduced risk of conductor damage, enabling reliable connections that can be further strengthened by soldering or welding, thus simplifying and improving the connection process.
Implementation Method 1
The connecting piece creates a press connection between the conductors
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a conductor connection (100) comprising a connection part (1) and several electric conductors (2, 3). The connecting part (1) has two or more openings (7, 8). The conductors (2, 3) extend respectively through one of the openings (7, 8) into the connection part (1). The connection part (1) comprises a wall (11), the distance (a) thereof from a longitudinal axis (6) of the connection part (1) increasing to at least one of the openings (7, 8). The connection part (1) is designed in particular as a curved strip part (18) with overlapping lateral regions (14, 15).