Segmented Contact Pin Rigidity for Reduced Contact Wear

Solution Overview

Problem

Existing contact pins in vehicle electronics are not adequately designed to withstand significant mechanical and thermal loads, particularly in applications where relative movements between connected components occur, leading to excessive wear and potential failure.

Innovation Solution

A contact pin design featuring a first component longitudinal portion with higher rigidity and a second component longitudinal portion with lower rigidity, allowing for elastic deformation under load, thereby reducing wear and maintaining favorable mounting properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If the contact pin is made rigid to ensure stable mounting, then mounting stability is improved, but wear in the contact zone increases due to inability to accommodate relative movements

Engineering Contradiction:

Improvemounting stabilityVSAvoidcontact zone wear

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The contact pin is divided into two distinct segments: a first component longitudinal portion with greater rigidity for stable mounting, and a second component longitudinal portion with lower rigidity to accommodate relative movements and reduce wear. This segmentation allows each part to fulfill its specific function optimally.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different sections of the contact pin are assigned different rigidity properties according to their functional requirements. The first portion (mounting section) has high rigidity for stability, while the second portion (contact section) has low rigidity to absorb movements, creating local quality variation that resolves the contradiction.

Inventive Principle:

Principle #3Local quality

2Reliability

If the contact pin is made flexible to accommodate relative movements, then contact-zone wear is reduced, but mounting stability deteriorates

Engineering Contradiction:

Improvecontact-zone wear resistanceVSAvoidmounting stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The contact pin is divided into two distinct segments: a first component longitudinal portion with greater rigidity for stable mounting, and a second component longitudinal portion with lower rigidity to accommodate relative movements and reduce wear. This segmentation allows each part to fulfill its specific function optimally.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different sections of the contact pin are assigned different rigidity properties according to their functional requirements. The first portion (mounting section) has high rigidity for stability, while the second portion (contact section) has low rigidity to absorb movements, creating local quality variation that resolves the contradiction.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If the contact pin has high rigidity throughout, then mounting properties are favorable, but the pin cannot elastically deform under thermal and mechanical loads

Engineering Contradiction:

Improvemounting propertiesVSAvoidelastic deformation capability

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The contact pin is divided into two distinct segments: a first component longitudinal portion with greater rigidity for stable mounting, and a second component longitudinal portion with lower rigidity to accommodate relative movements and reduce wear. This segmentation allows each part to fulfill its specific function optimally.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different sections of the contact pin are assigned different rigidity properties according to their functional requirements. The first portion (mounting section) has high rigidity for stability, while the second portion (contact section) has low rigidity to absorb movements, creating local quality variation that resolves the contradiction.

Inventive Principle:

Principle #3Local quality

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 minimizes contact-zone wear and enhances mechanical stability while accommodating thermal and mechanical stresses, ensuring reliable connectivity under varying loads.

Implementation Method 1

The second component longitudinal portion of the contact pin is less rigid than the first component longitudinal portion and, depending on the loads acting on it (for example, mechanical loads on account of relative movements between components connected to the contact pin or thermal loads on account of heat transmission from the connected components to the contact pin), can elastically deform.

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS12512720B2Contact pin, support board and electrical machine

Publication Date: 2025.12.30 MELECS EWS GMBH & CO KG

AI summary

In order to create favorable structural conditions, at least one first component longitudinal portion and a second component longitudinal portion are provided, where the first component longitudinal portion has a greater level of rigidity than the second component longitudinal portion, such that thereby reducing contact zone wear is reduced, while favorable mounting characteristics are also created at the same time.