Disc-Shaped Connecting Element for Electrical Wire Assembly
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Solution Overview
Problem
Existing connectors for connecting multiple electrical wires to a common potential, such as ground, are complex and difficult to assemble, with limited adaptability and reliability in various applications.
Innovation Solution
A simple, easily assembled connecting element with variable projections made of conductive materials like copper or its alloys, which can be stamped or curved, allowing for crimp connections and embedded in a moisture-proof cover, facilitating connections between wires and a common wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multi-component connectors with screw terminals or locking elements are used, then reliable electrical connection is achieved, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent merges multiple traditional connector components (contact elements, locking mechanisms, terminal structures) into a single integrated connecting element made of conductive rubber. This unified structure eliminates the need for separate screw terminals, locking elements, and contact pieces, thereby reducing device complexity while maintaining reliable electrical connection through the inherent elasticity and conductivity of the rubber material
Solution Approach 2:
The conductive rubber connecting element performs multiple functions simultaneously: it provides electrical conduction, mechanical connection, elasticity for contact pressure, and flexibility for assembly. This multi-functional design replaces traditional specialized components (screw terminals for connection, springs for pressure, locks for securing) with a single versatile element that achieves all functions through its material properties and geometric design
2Adaptability or versatility
If traditional fixed-design connectors are used, then manufacturing consistency is maintained, but adaptability to different wire configurations is limited
Solution Approach 1:
The connecting element incorporates elastic deformation capability through its conductive rubber material and geometric design, allowing it to dynamically adapt to different wire sizes, shapes, and configurations. The elasticity enables the element to deform during assembly to accommodate various conductor dimensions while maintaining consistent electrical contact pressure, eliminating the need for multiple fixed-design connector variants
3Reliability
If complex assembly procedures are used, then connection reliability is ensured, but assembly time and labor requirements increase
Solution Approach 1:
The connecting element is pre-formed with optimized geometry and elastic properties during manufacturing, so that upon insertion it automatically deforms to the correct configuration and establishes reliable electrical connections without requiring complex assembly steps. The preliminary preparation of the elastic structure enables plug-and-play assembly, dramatically reducing assembly time while maintaining connection reliability through the pre-engineered contact mechanics
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
The solution simplifies the connection process, enhances adaptability, and ensures reliable electrical conductivity while being easy to manufacture and assemble, suitable for various applications including motor vehicles.
Implementation Method 1
A connecting element (1) designed as a disc or plate is used to connect the wires, which has a number of outwardly protruding projections (2) on its peripheral surface
Implementation Method 2
The connecting element is embedded in a moisture-proof cover with the connected conductors or wires
Data Source
Figure 1~3
AI summary
An arrangement for electrically connecting at least two electrical conductors to a further electrical conductor is described, comprising an electrically conductive connecting element (1) equipped with connection points for each conductor, wherein the conductors each consist of an electrical conductor surrounded by insulation. The connecting element (1) is a disc-shaped component made of metal, having a number of outwardly projecting, mutually separated projections (2, 5) corresponding to the number of conductors to be connected, each of which serves as the electrically conductive connection for a conductor of an electrical conductor.