Electrical Connector With Segmented Conducting Element
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Solution Overview
Problem
Existing electrical connectors for injectors in internal combustion engines face challenges in reliability and precision due to high mechanical forces and pressure waves, which can lead to electrical disconnection and potential damage during fluid injection under high pressures.
Innovation Solution
An electrical connector design featuring a first rigid conducting element and a second elastically deformable conducting element, where the second element bridges the first to maintain electrical contact even under high mechanical stress, ensuring secure coupling and flexibility, with a structured attenuation zone for enhanced mechanical flexibility and ease of manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid conducting element is used to ensure stable electrical connection, then electrical stability is improved, but mechanical flexibility deteriorates under high pressure waves
Solution Approach 1:
The conducting element is divided into multiple sections with different rigidity characteristics. The first section has high rigidity for stable electrical connection, while the second section has lower rigidity to absorb mechanical stress from pressure waves, preventing damage to the actuator unit.
Solution Approach 2:
Different sections of the conducting element have different mechanical properties. The first section is designed with high rigidity for electrical stability, while the attenuation zone and second section have reduced rigidity to provide mechanical flexibility and stress absorption at specific locations.
2Reliability
If the conducting element is made highly rigid for stable power supply, then electrical stability is improved, but susceptibility to damage from high mechanical forces increases
Solution Approach 1:
The attenuation zone is designed beforehand with reduced cross-section to act as a cushion or sacrificial element. When pressure waves occur during fluid injection, this zone absorbs the mechanical stress through controlled deformation, protecting the more critical rigid sections and actuator unit from damage.
Solution Approach 2:
The attenuation zone converts the harmful effect of pressure waves into beneficial controlled deformation. By designing a specific section with lower rigidity, the harmful mechanical forces are redirected to deform this zone rather than damaging the actuator unit or causing electrical disconnection in critical areas.
3Adaptability or versatility
If the conducting element is made flexible to absorb pressure waves, then mechanical flexibility is improved, but electrical connection reliability deteriorates
Solution Approach 1:
The conducting element is segmented into different functional zones: a rigid first section for stable electrical connection to the power supply, and a more flexible second section with an attenuation zone for absorbing pressure waves. This segmentation allows each section to fulfill its specific function without compromising the other.
Solution Approach 2:
Different local sections of the conducting element have different rigidity properties tailored to their specific functions. The first section maintains high rigidity for electrical stability, while the attenuation zone and second section have reduced rigidity for mechanical flexibility, achieving both requirements in different locations.
4Reliability
If a complex multi-section conducting element is used to handle pressure waves, then reliability under stress is improved, but manufacturing complexity increases
Solution Approach 1:
The conducting element's cross-sectional parameters are changed along its length to create the attenuation zone. By reducing the cross-section at specific locations through controlled deformation or design, the element achieves different rigidity levels without requiring completely different materials or complex assembly processes.
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 a reliable and precise electrical connection to the actuator unit, maintaining secure power supply even under high mechanical forces, preventing damage to the injector and ensuring precise fluid injection.
Implementation Method 1
the second conducting element being elastically deformable and having a second rigidity being smaller than the first rigidity of the first conducting element
Implementation Method 2
the first conducting element being coupled electrically to the second conducting element in a manner that the second conducting element electrically bridges a section of the first conducting element
Data Source
Figure 1
Figure 2~3
AI summary
Electrical connector (30) for an injector (20) comprising a connector body (32), a pin (38) being mechanically coupled to the connector body (32) and being electrically coupable to a power supply, and an electric conductor (34) being electrically coupled to the pin (38) and being electrically coupable to an actuator unit (28) of the injector (20), the electric conductor (34) comprising a first conducting element (35) and a second conducting element (36), the first conducting element (35) having a first rigidity, the second conducting element (36) being elastically deformable and having a second rigidity being smaller than the first rigidity of the first conducting element (35), and the first conducting element (35) being coupled electrically to the second conducting element (36) in a manner that the second conducting element (36) electrically bridges a section (35c) of the first conducting element (35).