Deep-Drawn Plate Contact Receptacle for Thin High-Current Busbars
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Solution Overview
Problem
Existing power supply component arrangements, such as conductor rails and busbars, require significant material and cost due to the need for thick plate elements and time-consuming welding/soldering processes, which are inefficient for high-current applications.
Innovation Solution
A plate element with a collar section and recess design that allows for a reduced thickness, enabling press-fit connections without welding or soldering, utilizing deep drawing for material savings and improved conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the plate element thickness is reduced to save material, then material cost decreases, but the mechanical stability and current conduction capability may be insufficient
Solution Approach 1:
The invention transitions from a conventional through-hole design to a recess design where the hole does not penetrate the entire plate thickness. The collar section provides additional lateral support structure, creating a three-dimensional configuration that enhances mechanical stability while reducing material consumption in the thickness direction.
Solution Approach 2:
The collar section creates a localized thickening around the recess opening, concentrating material where it is most needed for mechanical support and contact stability. This local quality enhancement allows the overall plate thickness to be reduced while maintaining strength at the critical connection zone.
2Reliability
If welding or soldering processes are used to connect contact elements, then reliable material connection is achieved, but production time and cost increase
Solution Approach 1:
The invention replaces thermal joining processes (welding/soldering) with a mechanical press-fit system. The collar section's geometric design creates interference fit with the contact element, providing reliable mechanical connection through friction and geometric constraint rather than thermal bonding, thereby eliminating time-consuming welding operations.
Solution Approach 2:
The collar section is pre-formed with specific dimensional tolerances during plate manufacturing, preparing the connection interface in advance. This preliminary action ensures that the subsequent press-fit operation achieves reliable connection without requiring additional thermal processing steps.
3Loss of substance
If deep drawing process is used to form collar section, then material savings are achieved, but manufacturing complexity increases
Solution Approach 1:
The invention combines the collar section formation and recess creation into a single deep drawing operation. This merging of functions allows the complex three-dimensional feature to be manufactured in one step from a flat plate blank, avoiding the need for separate punching, bending, or forming operations that would increase manufacturing complexity.
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
Achieves over 50% material savings, reduces production costs, and enables efficient high-current transmission with low line resistances through cold welding and increased contact area.
Implementation Method 1
the collar section can be formed by cold forming, particularly by deep drawing
Implementation Method 2
The inserted contact pin rests on the circuit board with an edge area and contacts the contact zone located there in a pressing area. This contact zone is preferably cold-welded in a gas-tight manner
Data Source
Figure 1
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AI summary
The present invention relates to a plate element (10) for carrying current, having at least one cutout (12) for providing a contact receptacle for a contact element (32), wherein the plate element (10) has a thickness (22), wherein the plate element (10) has a collar section (16), which surrounds the at least one cutout (12), on at least one side (21). The present invention further relates to a component arrangement having a plate element of this kind, wherein the component arrangement further has a contact element which has at least two limb sections at one end, and wherein the at least two limb sections are each in contact with an inner surface of the at least one cutout. The invention further proposes a method for producing a plate element and a method for producing a component arrangement.