Female Electrical Contact Assembly with Zigzag Bent Segments
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing high-current female contact assemblies require stiff and expensive materials to achieve necessary normal forces, which reduces conductivity and increases costs, and typically have only a single contact point, leading to high contact resistance.
Innovation Solution
A high-current female contact assembly with conductive elements featuring bent segments, such as zigzag patterns, that engage the male contact at multiple discrete points, allowing for increased normal forces and reduced resistance using thinner, softer, and less expensive materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If thick and expensive slabs of copper or brass are used to achieve high normal forces, then the contact force is sufficient, but the cost increases and conductivity decreases
Solution Approach 1:
The patent applies curvature by forming bent segments (such as zigzag patterns) in the conductive elements. These curved configurations allow thinner, softer materials to generate high normal forces through elastic deformation when compressed, eliminating the need for thick expensive slabs while maintaining both force and conductivity
Solution Approach 2:
The patent changes the physical parameters of the conductive elements by introducing bent segments with specific geometries (zigzag patterns, undulations). This allows the use of thinner, softer, more conductive materials that can still achieve the required normal forces through elastic deformation, resolving the contradiction between force requirements and material cost/conductivity
2Force
If the leaves are hardened to achieve high normal forces, then the contact force is sufficient, but the useful life of the leaves is significantly reduced
Solution Approach 1:
The patent changes the approach to achieving high normal forces by using elastic deformation of bent segments instead of hardening. This allows the use of softer, more ductile materials that can undergo repeated elastic cycles without significant degradation, thereby extending the useful life while maintaining high contact forces
3Force
If alloying with grain hardening substances is used to achieve high normal forces, then the contact force is sufficient, but the conductivity of the leaves is reduced
Solution Approach 1:
The patent changes the method of force generation from material property modification (alloying) to geometric configuration (bent segments). This allows the use of pure, highly conductive materials that form elastic springs through their shape rather than through hardening alloys, thereby maintaining high conductivity while achieving sufficient normal forces
Solution Approach 2:
The patent effectively creates a composite structure by combining the conductive material with the geometric spring structure. The bent segments act as elastic elements that generate force without requiring conductive compromise, achieving both high force and high conductivity through structural design rather than material composition
4Device complexity
If single contact point design is used, then the structure is simple, but the contact resistance is high
Solution Approach 1:
The patent applies segmentation by dividing the contact interface into multiple discrete contact points along the bent segments. When the conductive elements are compressed, the zigzag patterns create multiple contact points with the male blade, distributing the electrical current and significantly reducing contact resistance while maintaining relatively simple overall structure
Solution Approach 2:
The patent transitions from a single-point contact (zero-dimensional contact area) to a multi-point contact distributed along the length of the bent segments (one-dimensional contact distribution). This dimensional change increases the effective contact area and number of parallel conduction paths, reducing contact resistance without significantly increasing structural complexity
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 solution effectively decreases electrical contact resistance and increases the number of contact points, enabling high-current applications with thinner, softer, and less expensive materials while maintaining high normal forces.
Implementation Method 1
the conductive element of the contact assembly acts like a leaf spring and produces relatively high normal forces
Implementation Method 2
the number of contact points between the conductive element and the male blade conductor is substantially increased, thereby decreasing the electrical contact resistance
Data Source
AI summary
An electrical connection device has a first end and a second end configured to be electrically coupled to a first conductor and a second conductor. A pair of conductive elements are arranged between the first end and the second end and configured for engagement with the first and second conductors. The conductive elements include a respective flat segment and a bent segment. The bent segments define an opening in which one of the first and second conductors are configured to be received. The bent segments include a number of corners configured to engage opposing sides of the one of the first and second conductors at a number of discrete points along at least a portion of the length of the at least one first and second conductors.