Crimped Contact Element with Segmented Coating Zones
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Solution Overview
Problem
Existing electrical contact elements lack improved electrical conduction and mechanical characteristics, and are not cost-efficiently manufactured in large quantities.
Innovation Solution
The contact surface features alternating regions with a first coating and uncoated regions, where the first coating covers surface offset zones, enhancing electrical conductivity and mechanical stability, and reducing material usage by strategically applying coatings only where needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the contact surface is completely coated with the first coating material, then electrical conductivity is improved, but material costs increase and manufacturing time increases
Solution Approach 1:
The contact surface is divided into different zones with different coating conditions: surface offset zones are coated with the first coating material to ensure electrical conductivity, while recesses remain uncoated or have different coating. This local differentiation allows coating material to be applied only where electrically conductive properties are critical, reducing overall material consumption while maintaining necessary conductivity performance.
Solution Approach 2:
The contact surface is segmented into surface offset zones and recesses, with the first coating material selectively applied to the surface offset zones. This segmentation enables precise control over where coating is applied, allowing the patent to reduce total coating material usage by excluding recess areas from the coating process while still providing adequate electrical conductivity at the critical contact interfaces.
2Reliability
If the contact surface is completely coated with the first coating material, then electrical conductivity is improved, but manufacturing duration increases
Solution Approach 1:
The coating process is optimized by applying the first coating material only to surface offset zones rather than the entire contact surface. This localized coating approach reduces the total surface area requiring coating, thereby shortening coating process duration while still ensuring electrical conductivity at the critical contact areas where surface offset zones are located.
Solution Approach 2:
Instead of coating the entire contact surface (excessive action), the patent applies coating only to the necessary surface offset zones (partial action). This partial coating approach is sufficient to achieve the required electrical conductivity performance while significantly reducing the time and resources needed for the coating process.
3Reliability
If large area coating is applied to the contact surface, then electrical conductivity is improved, but mechanical stability deteriorates due to twisting
Solution Approach 1:
The first coating material is applied selectively to surface offset zones rather than uniformly across the entire contact surface. This localized coating distribution maintains mechanical stability by avoiding excessive coating material that could cause twisting, while still providing adequate electrical conductivity at the critical contact interfaces where surface offset zones are positioned.
4Ease of manufacture
If the contact surface has uniform coating coverage, then manufacturing simplicity is maintained, but material costs and manufacturing time increase
Solution Approach 1:
The contact surface is differentiated into surface offset zones and recesses, with coating applied only to the surface offset zones. This local quality approach maintains manufacturing simplicity by using a straightforward coating process while reducing material consumption, as the coating is applied selectively rather than uniformly across the entire surface.
Data Source
Figure 1~2
Figure 3A~3B
Figure 4~5
AI summary
The invention relates to an electrical contact element (3), in particular for a crimp connection, wherein the contact element (3) is made from an electrically conductive contact material (5) and has at least one contact surface (7) for establishing an electrical connection with another conductive element, wherein the contact surface (7) has regions (13) with a first coating (15) and regions (17) without the first coating (15), and that the regions (13, 17) are arranged along at least one direction of variation (19, 35) in an alternating manner. In order to provide an electrical contact element (3) which can establish an improved electrical and mechanical connection to a conductive element such as a cable or strands and which at the same time can be produced cost-efficiently, the invention provides that the contact surface (7) has at least one recess (10), wherein at least one region (13) with the first coating (15) covers a surface offset zone (25) between the recess (10) and the rest of the contact surface (7) at least in sections, and in that the at least one direction of variation (19, 35) follows the course of a surface offset zone (25) and the surface offset zone (25) is covered at least in parts by regions (13) with the first coating (15).