Folded Contact Element Design for Electrical Connections
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Solution Overview
Problem
Existing contact elements for electrical connections are complex and expensive to produce due to the need for multiple machining processes and material removal, which results in inefficient material usage and high production costs.
Innovation Solution
A contact element design featuring a multi-layer structure with a larger plug-side cross-section and a smaller conductor-side cross-section, incorporating a reinforcement area with securing elements to prevent deformation, and a latching tongue with a spacer system that allows for easy assembly and disassembly without the need for complex connection techniques like welding or soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional machining processes are used to manufacture contact elements, then the contact element can be produced with sufficient strength, but the production process becomes complex and expensive with high material waste
Solution Approach 1:
The contact element is divided into distinct functional zones: a plug-side end with larger cross-section for mechanical strength and repeated connections, and a conductor-side end with smaller cross-section for crimping. This segmentation allows each zone to be optimized for its specific function without requiring complex machining of the entire component.
Solution Approach 2:
Different regions of the contact element are given different material properties and geometries suited to their local requirements. The plug-side end has thicker material and larger cross-section for strength, while the conductor-side end has thinner material for easy crimping. This local differentiation eliminates the need for complex machining operations.
2Strength
If traditional machining processes are used to manufacture contact elements, then the contact element can be produced with sufficient strength, but material waste increases due to removal
Solution Approach 1:
The cross-sectional parameters of the contact element are varied along its length rather than being uniform. The plug-side end has a larger cross-section parameter for strength, while the conductor-side end has a smaller cross-section parameter for crimping compatibility. This parameter variation allows the component to be formed from a single piece of material without extensive removal.
Solution Approach 2:
Instead of creating the varying cross-section through material removal in three dimensions, the design uses a two-dimensional approach by forming the contact element from a flat sheet or strip of contact material that is then bent and folded. This dimensional approach significantly reduces material waste compared to traditional machining.
3Strength
If the plug-side end has thick material for strength, then the contact element can withstand repeated connections, but the conductor-side end requires material thickness reduction for crimping
Solution Approach 1:
The contact element is segmented into distinct zones with different material thicknesses: a thicker plug-side end for strength and a thinner conductor-side end for crimping. This segmentation is achieved through forming processes that create the thickness variation without requiring machining or joining operations.
Solution Approach 2:
The material thickness is locally optimized for each functional requirement. The plug-side end maintains greater thickness to withstand mechanical stresses from repeated connections, while the conductor-side end has reduced thickness to facilitate crimping onto conductors. This local quality differentiation is built into the component geometry.
4Shape
If sections of different thicknesses are joined to form a contact element, then the desired strength and geometry can be achieved, but the production process becomes complex and expensive
Solution Approach 1:
Multiple functional zones with different thicknesses are merged into a single monolithic contact element formed from one piece of contact material. The varying thickness profile is achieved through forming, bending, and folding operations rather than joining separate sections. This eliminates the need for complex joining processes such as welding or mechanical fastening.
Solution Approach 2:
The varying thickness profile and geometric features are prepared in advance during the forming process, rather than requiring subsequent joining operations. The contact element is pre-formed with the correct thickness variations and geometries for both the plug-side and conductor-side ends, eliminating the need for complex assembly processes.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a contact element (1) of an electrically conducting contact material (4) for establishing an electrically conducting connection, with a connector end (3) for plugging into a complementary mating contact element, particularly a socket, and a conductor end (5), to which an electrical conductor can be fastened, wherein a connector-end cross-section (17) of the contact element (1) is larger than a conductor-end cross-section (19), and a method for producing a contact element (1). In order to be able to produce contact elements (1) quickly and at low cost, it is proposed according to the invention that there is at least one fold (7) of the contact material (4) at the connector end (3) and that the contact material (4) is folded over at least once from the contact end (3) towards the conductor end (5).