Electrical Connection Device for Flexible Elements
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Solution Overview
Problem
The structural fragility of flat, flexible electrically conductive elements, such as those used in vehicle heating systems, makes them prone to deformation and rupture under mechanical stress, leading to instability in electrical connections, especially in environments with vibrations and impacts.
Innovation Solution
An electrical connection device with a first jaw and a second jaw that compresses the flexible element between them, featuring recesses and protrusions for secure snap-fitting, distributing compression forces and reducing punctual stress, while allowing for double electrical contact and improved material efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal electrical connector is used to establish electrical connection with the flat flexible element, then electrical conductivity is improved, but the structural fragility of the element causes deformation and rupture under mechanical stress
Solution Approach 1:
The patent introduces a compliant contact element as an intermediary between the rigid electrical connector and the fragile flat flexible element. This compliant contact element deforms under compression to establish electrical connection, absorbing mechanical stress and preventing direct transmission of force to the fragile element, thereby resolving the contradiction between electrical conductivity and mechanical strength
Solution Approach 2:
The patent changes the mechanical parameters of the contact system by using a compliant contact element with specific elasticity properties. The contact element is designed to deform within a controlled range (e.g., 0.1-5mm compression distance) to establish reliable electrical connection while limiting the mechanical stress transmitted to the flat flexible element, thus maintaining both electrical conductivity and element integrity
2Reliability
If compression force is applied to establish electrical contact, then electrical conductivity is improved, but the punctual stress causes deformation and rupture of the fragile element
Solution Approach 1:
The patent segments the contact interface by introducing a compliant contact element that distributes the compression force over a larger surface area. Instead of concentrating stress at a single punctual contact point, the compliant element spreads the load across its contact surface with the flat flexible element, reducing punctual stress while maintaining electrical conductivity
Solution Approach 2:
The patent implements beforehand cushioning by designing the compliant contact element to absorb and distribute compression forces before they reach the fragile flat flexible element. The elastic properties of the contact element act as a cushion, preventing excessive punctual stress during connection establishment and under subsequent mechanical loads
3Adaptability or versatility
If the flat flexible element is made thinner and more flexible, then adaptability and flexibility are improved, but the risk of deformation and rupture under mechanical stress increases
Solution Approach 1:
The patent uses the compliant contact element as a protective intermediary that shields the thin, flexible flat flexible element from direct mechanical stress. This allows the element to maintain its thin and flexible characteristics for adaptability while the contact element absorbs and distributes external forces, preventing deformation and rupture
Data Source
AI summary
An electrical connection device includes a first jaw and a second jaw facing the first jaw in a closed state. The first jaw has a first insertion surface perpendicular to an insertion direction into a connection casing, a first surface facing the second jaw that is substantially parallel to the insertion direction, and an opposite first surface opposite the first insertion surface. The first jaw has a first recess. The second jaw has a second surface facing the first jaw and extending substantially parallel to the insertion direction, a second insertion surface introduced over the connection casing and perpendicular to the insertion direction, and an opposite second surface opposite to the second insertion surface. The second jaw has a second recess facing the first recess in the closed state. The first recess and/or the second recess has a rod at the first edge and/or the second edge.