Flexible Element for Electrical Contact Sealing

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Solution Overview

Problem

Existing contacting devices fail to achieve satisfactory sealing and low contact resistance when used with electrical conductors having insulating materials with tolerances or non-smooth outer surfaces, such as braided or woven layers.

Innovation Solution

A flexible element with an adhesive portion that adheres to the insulating material and a non-adhesive portion that contacts the conducting core is used, allowing for improved sealing and electrical conductivity, even on non-smooth surfaces, by being placed over the conducting core before installing a conventional contacting device.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a clamp-like contacting device is installed on the conducting core to provide electrical contact, then electrical conductivity is improved, but sealing against external influences deteriorates due to insulating material tolerances

Engineering Contradiction:

Improveelectrical contact reliabilityVSAvoidsealing against humidity and dust

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A flexible sealing element is introduced as an intermediary component between the contacting device and the insulating material. This sealing element compensates for tolerances in the insulating material and ensures both reliable electrical contact and effective sealing against humidity and dust, resolving the contradiction between electrical conductivity and sealing performance.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The sealing element is designed as a flexible thin film or shell that can adapt to variations in insulating material dimensions. This flexibility allows the sealing element to maintain contact and sealing effectiveness despite tolerances in the insulating material, while the contacting device maintains electrical conductivity.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If a clamp-like contacting device is installed to provide electrical contact, then electrical conductivity is improved, but contact resistance increases on non-smooth surfaces

Engineering Contradiction:

Improveelectrical contact reliabilityVSAvoidcontact resistance on non-smooth surfaces

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The flexible sealing element conforms to non-smooth surfaces of the conducting core, ensuring consistent contact pressure and low contact resistance. The flexibility of the sealing element allows it to adapt to braided or woven outer conducting layers, eliminating air gaps and improving electrical conductivity.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The sealing element changes its physical parameters (shape, thickness) through elastic deformation to match the surface topology of the conducting core. This parameter adaptation ensures uniform contact pressure across non-smooth surfaces, reducing contact resistance and improving electrical reliability.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the conducting core is exposed to provide electrical contact, then electrical conductivity is improved, but protection against external influences deteriorates

Engineering Contradiction:

Improveelectrical contact reliabilityVSAvoidprotection against humidity and dust

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The flexible sealing element serves as a mediator that allows the contacting device to access the conducting core for electrical contact while simultaneously providing a barrier against humidity and dust. The sealing element is positioned between the external environment and the exposed conducting core, enabling both electrical conductivity and protection.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The sealing element forms a flexible protective shell or film over the exposed conducting core area. This thin film structure allows electrical contact to be made while maintaining protection against external influences, as the flexible material can accommodate the contacting device while still providing a sealing barrier.

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

This solution provides enhanced sealing protection against humidity and dust, achieving low contact resistance and improved electrical conductivity, especially on conductors with non-smooth surfaces, while adapting to various materials and tolerances.

Implementation Method 1

a flexible element with an adhesive portion that adheres to the insulating material

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentEP1956683B1Method of contacting an electrical conductor and flexible element for providing an electrical contact

Publication Date: 2010.06.16 ALCATEL LUCENT SA

Figure 1~2
Figure 3~4

AI summary

A method of contacting an electrical conductor (1) having a conducting core (2) covered partly by an insulating material (3), comprising installing a contacting device (10) in electrical contact with the conducting core in a position (4) where the conducting core is free from the insulating material. Said method further comprises a flexible element (5) comprising an electrically conducting material over the conducting core in said position prior to installing the contacting device, the flexible element comprising at least one adhesive portion (8) which adheres to the insulating material in a vicinity of said position and a non-adhesive portion (7) which contacts the conducting core.