Contact Stud with Protection Element for Car Body Grounding
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Solution Overview
Problem
The current method of establishing a ground connection in car electrical installations using threaded connections is time-consuming and prone to damaging aluminum car bodies, which are softer than iron-based metals.
Innovation Solution
A contact stud with a protection element that shields the conductive section from coatings, allowing easy access for electrical contact, and a terminal with a contact spring and seal for secure and efficient connection, eliminating the need for threads and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a threaded connection is used to establish ground connection, then the electrical connection can be made, but the manufacturing process becomes time-consuming
Solution Approach 1:
The invention extracts and eliminates the threaded connection component from the grounding system. Instead of using a threaded bolt and nut assembly, the patent employs a simple insertion connection where the contact stud is directly inserted into the terminal opening, removing the time-consuming threading operation entirely while maintaining reliable electrical contact through the contact spring and conductive sections.
Solution Approach 2:
The contact stud is segmented into distinct functional sections: a base section for mounting to the car body, a connection section with electrically conductive portions for electrical contact, and an insulating section for protection. This segmentation allows each part to perform its specific function efficiently, with the conductive sections providing reliable electrical connection and the insulating section preventing unwanted conductivity.
2Reliability
If threads are used for connection on aluminum car body, then the connection can be established, but the threads are often damaged during screwing process
Solution Approach 1:
The invention completely removes the threaded connection mechanism from the system. The contact stud features a base section that is inserted into the terminal opening and secured without requiring threads in the aluminum car body. This eliminates the problem of thread damage during the screwing process while maintaining secure mechanical and electrical connection.
Solution Approach 2:
The terminal acts as an intermediary component between the contact stud and the car body. Instead of directly threading into the soft aluminum, the contact stud connects to the terminal, which then provides the secure mounting to the car body structure. This intermediary approach protects the aluminum from thread damage while ensuring reliable connection.
3Reliability
If the connection section is exposed, then electrical contact can be made, but the connection section gets coated with insulating coating
Solution Approach 1:
The contact stud employs local quality differentiation with distinct conductive and insulating sections. The connection section contains electrically conductive portions (first and second conductive sections) that make electrical contact, while an insulating section is positioned to protect these conductive areas from insulating coatings. This local differentiation ensures that only the necessary areas are exposed for electrical contact while protecting other areas from harmful coating contamination.
Solution Approach 2:
The insulating section is pre-positioned on the contact stud to protect the conductive connection sections before the insulating coating is applied to the car body. This preliminary protective action prevents the coating from contaminating the electrical contact surfaces, ensuring maintained conductivity after coating application.
Data Source
Figure 1~2
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Figure 5~6
AI summary
In order to provide a solution that allows a more time efficient manufacturing, the application shows a contact stud (1) in particular for providing a connection to a car body (C), comprising a protection element (2), a connection section (3) adapted to be inserted into a ground terminal (20) along an insertion direction (5) and a base section (6) adapted to be mounted on a car body (C) wherein a first section (11) of the connection section (3) is protected from being coated by a coating (7) by the protection element (2) and the connection section (3) outside the first section (11) is coated with an insulator. Further, a terminal (20) in particular for car technology is adapted to receive a contact stud (1) in an insertion direction (5), comprising a receptacle (22) with an opening (31) that is open in the insertion direction (5) and a contact spring (24) in the receptacle (22), the contact spring (24) comprising a contact surface (21) protruding inwardly into the receptacle (22). A contact assembly (40) in particular for car technology comprises a contact stud (1) and a terminal (20).