Contact Element Form-Fixing for High Current Assembly
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Solution Overview
Problem
Conventional contact elements with high current-carrying capacity are expensive to manufacture and require complex connections, with difficulties in fixing the contact lamella during the insertion and removal of connector parts, leading to economic inefficiencies, especially for small quantities.
Innovation Solution
A contact element with a form-fitting device molded into the contact body's surface, allowing the contact lamella to be positively engaged and fixed along the insertion direction, eliminating the need for additional fixing measures and enabling connection of electrical conductors via a tangentially protruding lug section, which can be connected in various orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact elements are manufactured as stamped parts with tab engagement to close the contact body, then the current-carrying capacity can be increased, but the manufacturing cost increases and production becomes more complex
Solution Approach 1:
The invention extracts the tab engagement closing mechanism from the contact body design. Instead of closing the contact body circumferentially via tab engagement, the contact body is designed as an open structure where the contact lamella is fixed to the contact body in a simplified manner, eliminating the need for complex tab engagement and reducing manufacturing cost while maintaining high current-carrying capacity through the solid copper contact body
Solution Approach 2:
The contact element is segmented into distinct functional components: the contact body for current conduction, the contact lamella for electrical contact and elastic pressure, and the fixing mechanism. This segmentation allows each component to be optimized independently - the contact body can be solid copper for high current capacity while the contact lamella provides the necessary elastic contact pressure, simplifying the overall manufacturing process
2Reliability
If the contact lamella is fixed to the contact body using lugs that grip the contact body edges, then the contact lamella can be secured during connector insertion and removal, but the production cost further increases
Solution Approach 1:
The invention removes the complex lug gripping mechanism from the design. Instead of using lugs that grip the contact body edges, the contact lamella is fixed directly to the contact body through a simplified fixing mechanism that reduces production cost while ensuring the contact lamella remains secured during connector insertion and removal operations
Solution Approach 2:
The contact lamella's own structure is utilized for fixation. The contact lamella is designed with features that enable it to be fixed to the contact body without requiring separate fixing components like lugs. The elastic nature and structural design of the contact lamella itself provide the means for secure attachment during connector operations
3Reliability
If electrical conductors are connected axially behind the plug-in area of solid contact sleeves, then reliable electrical contact is achieved, but the axial installation space requirement increases
Solution Approach 1:
The invention changes the dimension of conductor connection from axial (behind the plug-in area) to radial/lateral (at the side of the contact body). The contact body is designed with an opening that allows electrical conductors to be connected at the side, perpendicular to the axial direction. This dimensional change reduces the axial installation space requirement while maintaining reliable electrical contact through the solid copper contact body
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 simplifies the manufacturing process, reduces production costs, and allows for a compact design with a small axial space requirement, ensuring reliable electrical contact without additional reshaping or complex connections.
Implementation Method 1
the (elastically resilient) contact lamella ensures favorable electrical contact with elastic contact pressure on the connector part
Data Source
Figure 1~3
Figure 4~6B
Figure 7~9
AI summary
The invention relates to a contact element (1), comprising a contact body (10) extended in a strip-shaped fashion, said contact body being bent such that the contact body (10) forms an opening (120), into which a plug-in connector part (3) can be inserted in a plug-in direction (E), wherein the contact body (10) has a surface (104) extended around the opening (120) forming an inner wall of the opening (120). In the opening (120) of the contact body (10), a contact lamella (2) for electrically contacting a plug-in connector part (3) inserted into the opening (120) is arranged, and rests against the surface (104). According to the invention, the strip-shaped contact body (10) has a form-locking device (11) having at least one form-locking element (111-118) that is formed on the surface (104) of the contact body (10), wherein the contact lamella (2) is in form-locking engagement with the form-locking device (11), and is thus fixed on the contact body (10) along the plug-in direction (E). In this way, a contact element is provided that allows a simple, cost-effective production, even when designed for high current carrying capacity.