Conical Electrical Contact Surface Area for High Current Testing
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Solution Overview
Problem
Existing electrical contact arrangements for testing devices are limited to small currents (up to 1 ampere) due to point contact configurations, and using larger test needles does not significantly improve this, restricting the ability to test devices with higher currents.
Innovation Solution
The design features a conical segment-shaped test contact point and contacting element with a conical segment-shaped contact tip, allowing for surface contact and enabling currents greater than 10 amperes by forming a surface contact with a conical test contact surface on a printed circuit board, which also facilitates easy alignment and tolerance compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a point contact configuration is used, then the device structure is simple, but the maximum current is limited to 1 ampere
Solution Approach 1:
The contacting element features a conical contact tip with a curved surface that mates with a conical recess in the test contact point. This curved surface geometry transforms the traditional point contact into a surface contact, increasing the contact area and enabling higher current flow (greater than 10 amperes) while maintaining structural simplicity.
2Power
If larger test needles are used, then the contact area increases, but the improvement in current capacity is not significant
Solution Approach 1:
The conical contact tip with its curved surface automatically aligns with the conical recess during insertion, providing self-alignment that compensates for manufacturing tolerances. This eliminates the need for precise manual alignment while creating an extended surface contact area that significantly increases current capacity beyond 1 ampere.
Solution Approach 2:
The invention changes the contact geometry parameters from a traditional cylindrical or flat contact tip to a conical shape with specific angular parameters. This parameter change transforms the contact mode from point to surface contact, enabling current capacity greater than 10 amperes while the conical geometry provides self-aligning characteristics that improve ease of operation.
3Power
If a surface contact configuration is implemented, then current greater than 10 amperes is enabled, but the contact geometry becomes more complex
Solution Approach 1:
The conical contact tip and conical recess form a complementary curved surface geometry that enables surface contact for high current application. Despite the curved surface requirement, the conical shape is manufacturable using standard processes and provides self-aligning characteristics that simplify assembly, balancing the need for high current capability with manufacturing practicality.
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 configuration allows for higher current testing (beyond 10 amperes) while ensuring reliable surface contact and alignment, enhancing the testing capabilities of electrical devices.
Implementation Method 1
The contact tip 14 of the contacting element 13 is designed in the shape of a cone segment and protrudes into the recess 9. The contact tip 14 has a first contact tip area 15, which is designed in the shape of a cone segment, and a second contact tip area 16, which is also designed in the shape of a cone segment, with its smallest diameter being larger than the largest diameter of the contact tip area 15. A contact area 17 of the contacting element 13 is formed by the contact tip area 16, which produces an advantageous surface contact with the recess 9 or the conductor element 11 of the recess 9.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to an electrical contact arrangement (18) comprising a test contact point (8) and a contacting element (13) which belongs to a testing device and is used to manually contact the test contact point (8). The test contact point (8) is embodied as a recess (9), and the contacting element (13) comprises a contact region (17) producing at least one linear contact with the recess (9).