Direct-Plug Cable End With Contact Lamellae for Large Cross Sections
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Solution Overview
Problem
Existing methods for connecting electric cables or lines with larger cross sections to contact elements are inefficient, costly, and complex, particularly in automotive applications where ease of assembly and reliability are critical.
Innovation Solution
A method to modify the end of an electric line, such as a stranded wire, by forming a plug contour with a flat surface and applying a contact strip with resilient lamellae, and optionally incorporating a fastening element, allowing direct plugging into a mating plug without additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connection methods (soldering, welding, crimping) are used for larger cable cross sections, then reliable electrical contact is achieved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The contact strip is divided into multiple resilient contact lamellae that can be independently formed and function. Each lamella acts as a separate contact element, allowing the contact strip to conform to the plug contour while maintaining reliable electrical contact. This segmentation simplifies the overall connection structure compared to conventional methods requiring multiple components.
Solution Approach 2:
The contact strip with resilient lamellae provides self-aligning and self-contacting capabilities. When plugged into the mating plug receptacle, the resilient lamellae automatically deform to establish electrical contact without requiring precise alignment or additional fastening operations. This self-service mechanism eliminates complex assembly procedures while ensuring reliable contact.
2Reliability
If conventional connection methods are used for larger cable cross sections, then secure attachment is achieved, but manufacturing cost increases
Solution Approach 1:
The contact strip combines multiple functions into a single component: electrical contact, mechanical attachment, and resilient compliance. By integrating these functions into one element that is directly applied to the cable, the invention eliminates the need for separate connectors, fasteners, and joining operations, thereby reducing manufacturing cost while maintaining secure attachment.
Solution Approach 2:
The resilient contact lamellae change their physical parameters (deformation, contact pressure) in response to the plugging action. This parameter change allows the contact strip to adapt to variations in cable dimensions and plug tolerances, ensuring secure attachment across different manufacturing tolerances without requiring expensive precision machining or additional adjustment mechanisms.
3Ease of manufacture
If detachable plug contacts are made of different material or reduced copper content, then cost is reduced, but connection reliability deteriorates
Solution Approach 1:
The contact strip is applied directly to the cable conductor surface, creating a localized contact interface. This local application ensures that the critical contact area maintains optimal material properties and direct metal-to-metal contact, while the rest of the cable structure can use cost-effective materials. The local quality principle allows differentiated material usage without compromising overall connection reliability.
4Reliability
If additional components are used for secure connection, then attachment reliability is improved, but device complexity and installation space increase
Solution Approach 1:
The contact strip integrates electrical contact and mechanical attachment functions into a single component. The resilient lamellae provide both the electrical pathway and the mechanical retention force when deformed during plugging. This merging of functions eliminates the need for separate contact elements, fasteners, and locking mechanisms, reducing component count while maintaining connection security.
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
Facilitates a simple, cost-effective, and space-saving connection that ensures secure attachment and resilience, suitable for automotive components with enhanced load capacity and ease of assembly.
Implementation Method 1
a contact strip (30), in particular a contact lamella strip, having a plurality of resilient contact lamellae (31) protruding from the contact strip
Data Source
AI summary
A cable or a line and a plug contour at a line end of an electric line, of a stranded wire, has the following steps. The electric line at the line end is pressed-formed to form a plug portion with at least one flat surface portion at this line end. A contact strip is formed with a plurality of resilient contact lamellae that protrude from the contact strip. The contact strip is applied and connected to the surface portion.