Contact Element With Inclined Webs And Torsion Sections
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Solution Overview
Problem
Existing contact elements with resilient webs suffer from high stress at connection points, requiring high-strength beryllium-containing copper alloys, which are expensive and pose environmental hazards due to beryllium release, and have limited durability and flexibility.
Innovation Solution
A contact element with parallel strips and inclined webs connected via torsion sections, featuring bulges and indentations for efficient contact and reduced deformation, allowing for increased robustness and flexibility without using beryllium, thus minimizing stress and material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-strength beryllium-containing copper alloy is used to withstand high stresses at joint areas, then strength is improved, but cost increases and harmful factors are generated due to beryllium release
Solution Approach 1:
The patent converts the harmful effect of high stress concentration into a benefit by redistributing the stress through the inclined web geometry. The web is designed with an inclination angle of 30-60 degrees relative to the strip, which transforms the stress distribution pattern and eliminates the need for beryllium-containing alloys while maintaining structural integrity
Solution Approach 2:
The patent changes the geometric parameters of the web structure, specifically the inclination angle and the shape of front and rear edges. By optimizing these parameters, the stress distribution is improved, allowing the use of ordinary copper alloys instead of high-strength beryllium-containing materials
2Stress or pressure
If web shape is designed to reduce deformation at joint area, then stress is reduced, but manufacturing complexity increases
Solution Approach 1:
The web is segmented into distinct functional zones: an inclined central portion for stress distribution, a front edge with protrusion for contact engagement, and a rear edge with recess for complementary mating. This segmentation allows each zone to be optimized independently while maintaining overall manufacturability through standard stamping processes
Solution Approach 2:
Different regions of the web are given different geometric qualities tailored to their specific functions. The inclined portion handles stress distribution, the front edge protrusion handles contact engagement, and the rear edge recess provides complementary mating. This local optimization reduces overall stress while maintaining ease of manufacture
3Duration of action of stationary object
If contact element is designed for robustness to increase number of contact cycles, then durability is improved, but flexibility in contact configurations is reduced
Solution Approach 1:
The contact element is designed with universal features that enable it to function in multiple contact configurations. The inclined web geometry and complementary edge profiles can accommodate various contact partners including flat contacts, pin contacts, and socket contacts, providing both durability and flexibility across different applications
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 design enhances durability, reduces mechanical stress, and allows for a wider range of contact configurations, increasing service life and flexibility while avoiding beryllium use, thus reducing environmental impact and production costs.
Implementation Method 1
The webs are resiliently connected to one of the strips via a first torsion section and to another of the strips via a second torsion section. The torsion sections are designed to be resilient, so that in a contact situation, the webs are constantly pressed against the contact parts by the spring action
Implementation Method 2
The webs are resiliently connected to one of the strips via a first torsion section and to another of the strips via a second torsion section. The torsion sections are designed to be resilient, so that in a contact situation, the webs are constantly pressed against the contact parts by the spring action
Data Source
Figure 1a~1b
Figure 2~4
Figure 5~6
AI summary
A contact element (1) comprises at least two strips (2, 3) which extend parallel to one another and in a longitudinal axis (L), and a row of webs (14), which are arranged between the strips (2, 3) and are contiguous with the strips (2, 3), wherein the webs (14) are connected resiliently to one of the strips (2, 3) via a first torsion section (4) and to another of the strips (2, 3) via a second torsion section (5) and are inclined with respect to the strips (2, 3) in the deformed state, with the result that a first contact section (6) extends above the strip and a second contact section (7) extends below the strip (2, 3), wherein the webs (14) each have a front web rim (8) and a rear web rim (9), which front web rim (8) has a bulge (10), and which rear web rim (9) has an indentation (11), which fits or is complementary to the bulge (10) of a directly adjacent web rim, wherein the bulge (10) provides said front contact section (6), and wherein the webs (14), to the side of the indentation (11), have two rear web sections (13), which provide the second contact section (7). Furthermore, the front web rim (8) and the rear web rim (9) extend from the first torsion section (4) as far as to the second torsion section (5), and the front web rim (8) and the rear web rim (9) of two directly adjacent webs (14) touch one another in the undeformed state over their entire length, in particular at least approximately.