Resilient Contact Element with Dual Spring Zones
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Solution Overview
Problem
Resilient electrical contact elements used in connecting components are prone to oscillation at specific mechanical frequencies, leading to micro-interruptions due to resonance, which can cause connectivity issues, especially in dynamic environments like motor vehicles.
Innovation Solution
The electrical contact element features two contact zones with distinct spring characteristics, ensuring that if one zone resonates at a specific frequency, the other remains stable, thus reducing the risk of micro-interruptions by reacting to different excitation frequencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a resilient electrical contact element is used to compensate for assembly tolerances, then the ease of operation is improved, but the reliability deteriorates due to resonance-induced micro-interruptions
Solution Approach 1:
The contact element is divided into multiple contact zones (first contact zone and second contact zone), each with different spring characteristics. This segmentation ensures that not all contact zones resonate simultaneously, preventing complete electrical connection failure even when one zone experiences resonance-induced micro-interruptions.
Solution Approach 2:
Different contact zones are assigned different spring characteristics (first spring characteristic and second spring characteristic) to create local variations in resonant frequencies. This ensures that each contact zone responds differently to excitation frequencies, reducing the probability of simultaneous resonance and maintaining reliable electrical connection.
2Adaptability or versatility
If the contact element is made resilient to accommodate vibrations, then the adaptability is improved, but the stability deteriorates due to oscillation at resonant frequencies
Solution Approach 1:
The contact element is segmented into multiple contact zones with different spring characteristics, causing each zone to have different resonant frequencies. This segmentation allows the contact element to adapt to vibrations while preventing synchronized oscillation across all zones, thereby maintaining stability.
Solution Approach 2:
The spring characteristics of different contact zones are deliberately varied to change their resonant frequencies. By adjusting these parameters, the contact element can accommodate vibrations without experiencing large-amplitude oscillations at a single resonant frequency, thus maintaining stability.
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
This design significantly reduces the occurrence of micro-interruptions by ensuring that only one contact zone oscillates at a time, maintaining a stable electrical connection even under dynamic conditions.
Implementation Method 1
the first contact zone behaves according to a first spring characteristic when a force is applied, whereas the second contact zone behaves according to a second spring characteristic when a force is applied
Implementation Method 2
the resonant frequency of each of the contact zones is determined, among other things, by their spring characteristic, so that the fact that the first contact zone behaves according to a first spring characteristic, whereas the second contact zone behaves according to a second spring characteristic, the two contact zones have different resonant frequencies and thus react to different excitation frequencies with particularly strong vibrations
Data Source
Figure 1~2
Figure 3A~5
Figure 6A~6B
AI summary
The element (110) has a contact zone (112) i.e. stamping part, and a contact zone (114), which are provided on the contact element in such a manner that the zones act with force effect according to load deflection curves, respectively. The contact zones comprise individual contacts with height extensions, respectively. The height extension of the zone (112) is larger than the height extension of the zone (114). The curves comprise different characteristics. The stamping part is made of a sheet metal, and the element is formed as an integrated section of a conductor rail (122).