Electrical Connection With Raised Edge Collar For Thin Sheet Metal
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Solution Overview
Problem
Existing electrical connections struggle to support high torques and transmit high currents, especially when used with thin sheet metals, as they can result in a reduced contact surface and increased resistance.
Innovation Solution
The electrical connection features a passage with a raised edge around the opening of the first component, which can be conical, and a bolt with a threaded section that deforms the contact ring, providing a larger contact surface and torque support through a non-rotationally symmetrical outer contour, allowing for efficient power transmission and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a through hole is used in the first component for receiving the contact ring, then the manufacturing is simple, but the contact surface is small and cannot support high torques
Solution Approach 1:
The invention transitions from a 2D through hole to a 3D passage with a raised edge collar, adding vertical dimension to the contact surface. The passage protrudes from the plane of the first component, creating a collar that provides additional contact area for the contact ring, thereby increasing torque support capability while maintaining manufacturing simplicity through stamping processes
2Length of moving object
If the sheet metal thickness is reduced, then the component becomes thinner and lighter, but the contact surface becomes too small to derive higher currents and support mounting torque
Solution Approach 1:
By creating a passage with a raised edge collar that protrudes vertically from the sheet metal plane, the invention adds dimensional depth to the contact surface. This allows thin sheet metal components to achieve sufficient contact area for high current transmission and torque support without increasing material thickness
Solution Approach 2:
The contact ring is nested within the passage formed in the first component, with the raised edge collar providing a containment structure. This nesting arrangement maximizes the utilization of the available space and ensures stable mechanical connection even with thin sheet metal
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 enhances the ability to handle high torques and maintain low electrical contact resistance, ensuring reliable power transmission and mechanical stability even with thin sheet metals.
Implementation Method 1
an electrically conductive, plastically deformable (contact) ring
Data Source
Figure 1~4
Figure 2~3
AI summary
The invention relates to an electrical connection comprising an, in particular plate-like, first electrically conductive component (6) which has an opening (10), said electrical connection also comprising a bolt (1) which has a head (3), which extends along a first longitudinal axis (l), and a thread section (5, 14), and an electrically conductive plastically deformable ring (2) with a sleeve section (7), which has a passage opening with a second longitudinal axis for receiving the bolt (1), and a bearing collar (8). The opening (10) in the first component (6) is provided with an aperture (11).