Electrical Component Connection via Mechanical Pressing
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Solution Overview
Problem
Existing electrical component supports in motor vehicles face challenges in reliable and protected connection to electrical components due to exposure to harsh environmental conditions and the need for soldering, which complicates manufacturing and increases material requirements.
Innovation Solution
A method where electrical contacts are pushed or bored through elastically or plastically deforming material in the base part of the electrical component support, allowing for non-positive connections that protect the conductor paths from environmental influences without the need for soldering, and enabling the use of less corrosion-resistant materials for conductor paths while ensuring reliable contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to connect electrical contacts to conductor paths, then reliable electrical connection is achieved, but manufacturing complexity and time increase
Solution Approach 1:
The patent replaces the thermal-mechanical soldering process with a purely mechanical pressing operation. Electrical contacts are connected to conductor paths by pressing them together under controlled force, eliminating the need for soldering equipment, heat treatment, and associated manufacturing complexity while maintaining reliable electrical connection.
Solution Approach 2:
The patent introduces an intermediary pressing device that applies controlled force between the electrical contact and conductor path. This intermediary mechanism ensures reliable mechanical and electrical connection without requiring thermal processes, thereby simplifying manufacturing while maintaining connection reliability.
2Reliability
If conductor paths are made from corrosion-resistant materials, then durability in harsh environments is improved, but mechanical stability and flexibility decrease
Solution Approach 1:
The patent employs composite material construction where conductor paths are made from mechanically favorable materials (such as steel or copper alloys) that provide both flexibility and strength. The pressing connection mechanism compensates for any corrosion susceptibility by creating a robust mechanical bond that maintains electrical connection reliability even in harsh automotive environments.
Solution Approach 2:
The patent applies local quality protection by covering conductor paths with insulating material in corrosion-prone areas while maintaining the mechanically optimized material composition in regions requiring flexibility and strength. This localized approach allows different material properties in different regions of the same component.
3Ease of operation
If contact lugs are left exposed for easy connection, then ease of connection is improved, but protection against environmental influences decreases
Solution Approach 1:
The patent implements a nested structure where electrical contacts are pressed into recesses or cavities within the housing. This nesting arrangement provides protective coverage against environmental influences while maintaining accessible connection interfaces, as the pressing operation can still access the contacts through controlled openings or from the assembly side.
Solution Approach 2:
The patent uses insulating material layers and housing structures that flexibly cover conductor paths and electrical contacts. These thin film-like protective layers shield against moisture and environmental factors while allowing the pressing connection process to penetrate through designated access points, thus balancing protection with connection accessibility.
4Strength
If thick conductor path material is used, then mechanical stability is improved, but flexibility for bending decreases
Solution Approach 1:
The patent optimizes the thickness parameter of conductor paths to achieve a balance between mechanical stability and bending flexibility. By carefully selecting and controlling the thickness parameter within specific ranges, the conductor paths gain sufficient structural stability for reliable electrical connection while retaining enough flexibility to be bent into required configurations during assembly.
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 method provides rapid, reliable, and protected electrical connections that reduce manufacturing complexity and material usage, while allowing for the use of materials like steel for enhanced mechanical stability and corrosion-resistant materials for contacts, effectively addressing environmental exposure and manufacturing challenges.
Implementation Method 1
electrical contacts (4) are pushed or bored through elastically or plastically deforming material (8) in the base part (1)
Implementation Method 2
electrical contacts (4) are pushed or bored through elastically or plastically deforming material (8) in the base part (1)
Data Source
AI summary
The invention relates to a method for connecting an electric component to an electrical component support and an electrical component for an electrical component support, in particular for a motor vehicle. According to the invention, an electric component is connected to an electrical component support which comprises a base part and an electrical conductor paths arranged therein. At least one electric contact connected to the electrical component is moved in the base part such that the electric contact is electrically connected to the conductor path. The invention also relates to two electric contacts which are connected to the electric components and which are connected, according to the claims, to two different conductor paths in the base part. Said electric components can comprise more than two electric contacts, which according to the claimed method, are connected to the conductor paths of the base part.