Conductive Contact Element via Wedge Groove Segmentation
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Solution Overview
Problem
Existing methods for manufacturing electrically conductive contact elements face challenges in achieving high speed and precision while maintaining mechanical stability and minimizing tolerances, as they require complex processes and deformation of materials which can lead to increased force and material hardening.
Innovation Solution
A method involving a metal strip with wedge-shaped grooves as predetermined breaking points, allowing for embossing of depressions that form elevations with minimal force, which are then separated to create contact elements with precise dimensions and improved mechanical stability, using materials like copper alloys with high elasticity and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex manufacturing processes are used to achieve high precision, then manufacturing precision improves, but productivity deteriorates
Solution Approach 1:
Wedge-shaped grooves are introduced as predetermined breaking points before the embossing process. This preliminary action weakens the metal strip at specific locations, allowing the elevations to separate cleanly during embossing without requiring complex post-processing. The breaking points are pre-positioned to ensure precise elevation separation while maintaining high manufacturing speed
Solution Approach 2:
The metal strip is segmented into specific regions by introducing wedge-shaped grooves that create predetermined breaking points. This segmentation allows individual elevations to be formed and separated independently during embossing, enabling precise dimensional control of each contact element feature while maintaining a simple, high-speed manufacturing process
2Manufacturing precision
If material deformation is increased to form elevations, then elevation shape control improves, but material hardening increases
Solution Approach 1:
Wedge-shaped grooves are introduced before embossing to create predetermined breaking points. This preliminary weakening of the material at specific locations allows elevations to form with minimal additional deformation force, reducing material hardening while maintaining precise control over elevation size and shape through the controlled separation at the groove locations
Solution Approach 2:
The metal strip is given different properties at different locations: the wedge-shaped grooves create localized weak points with reduced thickness, while the regions between grooves maintain full material strength. This local quality differentiation allows precise elevation formation at the groove locations without causing excessive hardening across the entire material
3Strength
If minimal force is used during embossing, then material hardening is reduced, but elevation formation precision deteriorates
Solution Approach 1:
Wedge-shaped grooves are introduced before embossing to create predetermined breaking points that guide where elevations will separate. This preliminary action ensures that even with minimal embossing force, the elevations separate precisely at the intended locations, maintaining high manufacturing precision while using less force that would otherwise cause material hardening
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 method enables the rapid and precise production of contact elements with enhanced mechanical stability and reduced material deformation, allowing for efficient electrical connections with precise control over elevation size and shape, improving contact pressure and conductivity.
Implementation Method 1
embossing of depressions spaced apart from one another in at least one of the two sides of the metal strip, so that elevations spaced apart from one another are formed on the opposite side of the metal strip
Implementation Method 2
the contact element must be able to compensate for tolerances in the distance between the components to be connected. A large spring deflection is required for this
Data Source
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AI summary
The invention relates to a method for manufacturing an electrically conductive contact element (1), the method comprising the following steps: a) providing a metal strip (10) with a top (11) and a bottom (12) opposite the top (11), b) introducing wedge-shaped grooves (13) extending longitudinally in the metal strip (10) as predetermined breaking points into the top (11) and/or the bottom (12) of the metal strip (10), so that strip sections (14) are formed which are bounded by the grooves (13), c) embossing spaced-apart depressions (20) into at least one of the two sides (11, 12) of the metal strip (10), so that spaced-apart protrusions (21, 22) are formed on the opposite side (12, 11) of the metal strip (10), wherein the embossing is carried out in such a way thatthat the metal strip (10) is cut at the predetermined breaking points in the area of the embossing points and at least one of the resulting cut surfaces (24) forms part of the edge of the protrusion (21, 22), d) transversely divide the metal strip (10) so that at least one contact element (1) in the form of a strip section (15) is formed, wherein the contact element (1) has at least one protrusion (21, 22). The invention further comprises a contact element (1) and a sleeve with such a contact element (1).