Eccentric Contact Pin Assembly for High Current Density

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Solution Overview

Problem

Conventional electrical connection arrangements often lack sufficient space to accommodate larger cable cross-sections, necessitating a reconfiguration of contacts and increased space, which is not feasible in many applications, especially in the automotive sector due to space constraints.

Innovation Solution

A multifunctional electrical connection arrangement featuring a socket with contact openings, a contact carrier, and compactly designed contact elements, including a contact plate and eccentrically arranged contact pins, allowing for variable configuration and connection of larger cable cross-sections without altering the socket, utilizing a welded connection for low contact resistance and high mechanical strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional electrical connection arrangements use standard contact configurations, then the structure is simple and easy to manufacture, but the available space is insufficient for connecting larger cable cross-sections

Engineering Contradiction:

Improveability to connect different cable cross-sectionsVSAvoidspace required in housing

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

The contact pin is arranged eccentrically (asymmetrically) on the contact plate, offset from the center by a specific distance. This asymmetric arrangement allows the contact element to accommodate larger cable cross-sections by creating an optimized contact geometry that fits within the limited housing space while maintaining electrical connection capability.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The contact pin protrudes from the contact plate in a direction perpendicular to the plate surface, utilizing the third dimension (height/depth) to achieve the necessary contact geometry. This vertical arrangement allows larger cable cross-sections to be connected without increasing the horizontal footprint in the housing plane.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Area of stationary object

If contact pins are arranged closer together to fit more contacts in limited space, then space utilization improves, but the ability to connect larger cable cross-sections deteriorates

Engineering Contradiction:

Improvespace utilization in housingVSAvoidability to connect larger cable cross-sections

Core Design Contradiction:

Area of stationary objectVSAdaptability or versatility

Solution Approach 1:

The eccentric arrangement of the contact pin on the contact plate creates an asymmetric contact geometry that optimizes space utilization. The offset position allows the contact element to accommodate larger cable cross-sections while maintaining compact dimensions suitable for limited housing space, effectively resolving the conflict between space utilization and adaptability.

Inventive Principle:

Principle #4Asymmetry

3Strength

If a welded connection is used between contact pin and contact plate, then mechanical strength and electrical conductivity improve, but manufacturing complexity increases

Engineering Contradiction:

Improvemechanical strength of connectionVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The contact pin and contact plate are merged into a single integrated contact element through welding, combining two separate components into one unified structure. This merging provides mechanical strength and ensures good electrical conductivity between the pin and plate, while the welding process is a standard manufacturing technique that balances strength requirements with manufacturing feasibility.

Inventive Principle:

Principle #5Merging (Combining)

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

Enables the transmission of higher current densities with larger cable cross-sections within existing space constraints, maintaining low contact resistance and mechanical stability, facilitating assembly and disassembly without specialized tools.

Implementation Method 1

The connection between the contact pins and the contact plate is a welded connection. During the welding, the contact pin and the contact plate are melted locally at a connection point and form a non-detachable connection with very high strength after solidification.

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentEP3394935B1Multifunctional connection assembly having an eccentrically arranged contact pin

Publication Date: 2021.07.28 AMPHENOL TUCHEL ELECTRONICS

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AI summary

The invention relates to a multi-functional electrical connection assembly for transmitting medium and high current densities, consisting of a socket (2) having contact openings (11), a contact carrier (12), a contact element (1) consisting of a contact plate (9), and a contact pin (4) which protrudes from the contact plate (9) and which is arranged eccentrically on the contact plate (9).