Current Conduction Composite With Tensile Installation Aid

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Solution Overview

Problem

Existing component composites for current conduction face challenges in applying press-fitting forces without causing damage or buckling, especially when components are made of different materials with varying coefficients of thermal expansion, requiring high compression forces over a large temperature range.

Innovation Solution

A component composite design where the holding section of the second component protrudes beyond the first component and has a reduced cross-sectional area for installation, allowing a tensile force to be applied instead of pressure, with optional features like a predetermined breaking point and axial stop for secure connection and easy handling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If press-fitting forces are applied to connect the second component into the through opening of the first component, then connection strength is improved, but the second component may buckle or be damaged

Engineering Contradiction:

Improveconnection strengthVSAvoidbuckling and damage to second component

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

Instead of applying compressive press-fitting forces to insert the second component into the through opening, the patent inverts the approach by using tensile forces. The holding section with reduced cross-sectional area acts as a draw-in aid, allowing the second component to be pulled through the opening rather than pushed in, thereby avoiding buckling while achieving secure connection

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The holding section with reduced cross-sectional area serves as an intermediary element between the installation aid and the connection section. This intermediary structure provides a gripping point for the installation aid, enabling force transmission without directly applying damaging press-fitting forces to the thin-walled connection section

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If high compression forces are generated to ensure sufficient connection forces for different materials, then connection reliability is improved, but the risk of damage to the second component increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoiddamage to second component

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent inverts the force application method from compression to tension. By using tensile forces through the holding section as a draw-in aid, the connection is established without subjecting the second component to damaging compression forces, thereby maintaining reliability while eliminating harm

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes the force application parameter from compressive to tensile. This parameter change fundamentally alters the installation process, allowing secure connection of different materials without the harmful effects of high compression forces on thin-walled components

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If the holding section has a reduced cross-sectional area for installation aid, then ease of installation is improved, but the structural integrity of the second component may be compromised

Engineering Contradiction:

Improveease of installationVSAvoidstructural integrity

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The holding section is segmented from the connection section by having a reduced cross-sectional area. This segmentation creates a distinct zone that serves as an installation aid, allowing easy gripping and force application while the connection section maintains its full cross-sectional area and structural integrity for reliable electrical connection

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The holding section has local quality differences with a reduced cross-sectional area specifically at the installation zone, while the connection section maintains its full structural properties. This local modification enables ease of installation without compromising the overall structural integrity where it is most needed

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS9160081B2Component composite of two components used for current conduction, method for manufacturing a component composite, and use of a component composite

Publication Date: 2015.10.13 ROBERT BOSCH GMBH

AI summary

A composite of two components which are used for current conduction, includes: a through opening formed in a first component; and a connection section of a second component which is insertable into the through opening in an installation direction so that a friction-locked connection in the form of a press-fit connection is formed at least regionally between the through opening and the connection section. The connection section and a holding section of the second component protrude beyond the first component in the area of the through opening in the installation direction in the installed state, and the holding section has at least one area for an installation aid which is reduced in cross section in relation to the cross-sectional area of the through opening.