Elastic Contact Contactor for Stable Battery Connection

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Solution Overview

Problem

Size variations in battery-side electric contactors can lead to unstable contact and excessive stress on contact pieces of electronic equipment-side electric contactors, resulting in improper electrical connections and potential plastic deformation.

Innovation Solution

An electric contactor design featuring a conductive guide pin with a head and shaft portion, and a conductive elastic thin plate spring contact with tubular pieces and contact pieces that extend along the shaft, allowing for elastic contact and reducing stress through an annular space, ensuring stable and positive electrical connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the battery-side electric contactor is manufactured with size variations, then manufacturing flexibility and cost are improved, but stable electrical contact and reliability deteriorate

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidstable electrical contact

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The contact piece is designed with elastic deformation capability, allowing it to adapt to size variations in the battery-side electric contactor. The elastic material and structure enable the contact piece to change its dimensional parameters dynamically, maintaining stable electrical contact despite manufacturing tolerances in the mating component.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The elastic contact piece acts as a cushioning element that absorbs the dimensional variations before they can affect electrical contact stability. By incorporating this elastic buffer in advance, the design prevents the transmission of size variation effects to the electrical connection interface.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Ease of manufacture

If the battery-side electric contactor has size variations, then manufacturing cost and flexibility are improved, but excessive stress on contact pieces increases leading to plastic deformation

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidcontact piece stress resistance

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The contact piece utilizes elastic deformation to accommodate size variations, changing its physical parameters temporarily without permanent damage. This elastic behavior allows the contact piece to absorb stress from dimensional mismatches and return to its original state, preventing plastic deformation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The elastic contact piece serves as a protective cushion that absorbs excessive stress before it can cause plastic deformation. This beforehand cushioning mechanism protects the contact piece from damage due to size variations in the battery-side electric contactor.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Manufacturing precision

If a rigid contact structure is used, then manufacturing precision is improved, but adaptability to size variations deteriorates

Engineering Contradiction:

Improvecontact structure precisionVSAvoidadaptability to size variations

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The contact piece is designed with elastic properties that allow it to change its dimensional parameters in response to size variations in the battery-side electric contactor. This parameter change capability provides adaptability while maintaining manufacturing precision through controlled elastic deformation rather than rigid dimensional matching.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The contact piece utilizes a flexible elastic material structure that can deform to accommodate size variations. This flexible design allows the precisely manufactured contact piece to adapt to dimensional variations in the mating component, combining manufacturing precision with adaptability.

Inventive Principle:

Principle #30Flexible shells and thin films

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 design prevents plastic deformation of contact pieces and maintains stable electrical contact by distributing pressure evenly, ensuring reliable power supply to electronic equipment despite size variations in battery-side contactors.

Implementation Method 1

the contact is made of a conductive and elastic thin plate spring material

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS7955143B2Electric contactor and electronic equipment

Publication Date: 2011.06.07 SONY GROUP CORP

AI summary

Disclosed herein is an electric contactor including, a guide pin, and a contact, wherein the guide pin is made of a conductive material and has a head portion and a shaft portion connected to the head portion, a tip of the shaft portion connected to the head portion being smaller in diameter than the head portion, the contact is made of a conductive and elastic thin plate spring material and has first and second tubular pieces and a plurality of contact pieces, the first tubular piece being wound around the tip of the shaft portion, the second tubular piece being wound around a base end of the shaft portion located on the opposite side of the head portion, and the plurality of contact pieces configured to connect the first and second tubular pieces together.