Foldable Electrical Contact Part for Vibration-Resistant Current Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical contact arrangements in vibration-vulnerable environments face challenges with current load capacity, reliability, and ease of connection and installation, particularly in distributing voltage across modular connection modules.
Innovation Solution
A foldable conductive metal sheet forming orthogonally arranged resilient component and bus blade contacts, with dual contact spring legs and a central core for enhanced current distribution and secure engagement, allowing for reliable connections in vibration-prone settings while being cost-effective and easy to install.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional knife contact parts and terminal contact parts are used for power supply connection, then the connection can be established between adjacent connection modules, but the current load capacity is insufficient and the connection reliability deteriorates in vibration-vulnerable environments
Solution Approach 1:
The contact part is segmented into two separate contact blades instead of using a single knife contact part. Each contact blade independently engages with the terminal contact part, distributing the current load across multiple contact points and improving both current load capacity and connection reliability in vibration environments.
Solution Approach 2:
The contact blades are arranged in a parallel configuration extending in the vertical direction, creating a multi-dimensional contact structure. This dimensional arrangement allows multiple contact surfaces to engage simultaneously with the terminal contact part, increasing the effective contact area and current load capacity without compromising reliability.
2Adaptability or versatility
If modular connection modules are wired together to form connection blocks, then electrical connection between modules is achieved, but the complexity of assembly and installation increases
Solution Approach 1:
The contact part design with multiple contact blades and terminal contact parts creates a universal connection interface that can be repeatedly engaged and disengaged. This universal design allows adjacent connection modules to be easily assembled and disassembled while maintaining reliable electrical connection, supporting modular expandability without increasing assembly complexity.
3Power
If multiple contact blades are used to increase current load capacity, then power distribution is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
Multiple contact blades are merged into a single integrated contact part component, and multiple terminal contact parts are combined into one unified structure. This merging approach increases current load capacity through multiple contact points while avoiding the complexity of assembling separate components, as everything is formed as integrated pieces.
Solution Approach 2:
The contact part utilizes elastic deformation and resilient properties of the contact blades to maintain continuous electrical connection. By changing the mechanical parameters (elasticity, resilience) of the contact blades, the design achieves reliable connection and high current load capacity without increasing structural complexity or manufacturing cost.
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 increases current load capacity, ensures reliable and continuous electrical connections even in vibration-vulnerable environments, and simplifies the connection process while maintaining cost-effectiveness and ease of production.
Implementation Method 1
both the first contact spring leg and the second contact spring leg comprise an orthogonally arranged contact blade segment... the contact blade segment includes two contact resilient legs
Implementation Method 2
a planar conductive metal blank having sections that are foldable to define pairs of resilient orthogonally arranged component contacts and bus blade contacts
Data Source
AI summary
An electrical contact arrangement includes a planar conductive metal blank having sections that are foldable to define pairs of orthogonally arranged component contacts and bus blade contacts. Connected with a first pair of opposed side edges of a horizontal rectangular core section of the blank are a pair of rectangular component contact sections that are upwardly bent to define a pair of component contacts for receiving therebetween an electrical component, such as a printed circuit board. Connected with the orthogonally arranged second pair of opposed side edges of the core section are a pair of rectangular support sections that are bent downwardly, whereby a corresponding pair of bus blade contact sections connected with corresponding edges of the support sections extend in vertical parallel spaced relation to define a pair of bus blade contacts adapted for insertion between the downwardly bent support sections of a corresponding second electrical contact arrangement.