Frustoconical Projection Penetrates Oxidized Metal Surfaces
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Solution Overview
Problem
Existing electrical connectors face challenges in forming strong connections with metal components, particularly those with anodized or oxidized surfaces, as the coatings inhibit electrical contact.
Innovation Solution
An electrical connector with a frustoconical projection that penetrates the surface coating to establish a direct electrical connection, featuring a central aperture for receiving a fastener and an integrally formed electrical terminal for coupling with an electrical cable, ensuring reliable contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical connectors are used on anodized or oxidized metal surfaces, then the connectors can be easily installed, but the electrical connection quality deteriorates due to coating interference
Solution Approach 1:
The connector body is segmented into multiple functional zones: a planar contact surface for general contact, frustoconical projections for penetrating through coatings to reach bare metal, and a central aperture for fastener reception. This segmentation allows different portions of the connector to serve different purposes - the frustoconical projections specifically address the coating interference problem by mechanically breaching the anodized or oxidized layers to establish reliable electrical contact with the underlying metal.
Solution Approach 2:
The connector employs local quality by providing different surface characteristics in different locations. The frustoconical projections have a tapered geometry that concentrates force onto a small area, enabling them to penetrate coatings effectively. Meanwhile, the planar contact surface provides a larger area for stable electrical contact. This localized differentiation of contact properties allows the connector to simultaneously address both coating penetration and reliable electrical connection needs.
2Reliability
If the connector uses frustoconical projections to penetrate surface coatings, then electrical connection reliability improves, but the device complexity increases
Solution Approach 1:
The invention merges multiple functions into a single integrated connector body. The frustoconical projections, planar contact surface, and central aperture are all formed as part of one unitary structure rather than separate components. This merging approach achieves reliable electrical connection through coating penetration while avoiding the complexity of assembling multiple separate parts, as the entire connector can be manufactured as a single piece with varied surface geometries.
Solution Approach 2:
The connector utilizes parameter changes in its geometry to achieve different functions. The frustoconical projections feature a specific tapered angle and depth that enables coating penetration, while the planar contact surface provides a different geometric parameter (flat, extended surface) for stable contact. By varying geometric parameters within a single component design, the connector achieves multifunctionality without proportionally increasing complexity.
3Reliability
If the connector is designed to penetrate metal surface coatings, then electrical contact is ensured, but the manufacturing precision requirements increase
Solution Approach 1:
The frustoconical projections are pre-formed during connector manufacturing with their tapered geometry already established. This preliminary formation of the penetrating features eliminates the need for field modification or adjustment during installation. The projections are manufactured to their final dimensions, ensuring consistent coating penetration capability without requiring high precision adjustment during assembly, thereby reducing the practical manufacturing precision burden while maintaining reliable electrical contact.
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 connector effectively penetrates surface coatings to provide a strong, durable electrical connection between metal components and electrical cables, even in the presence of corrosion or oxidation layers.
Implementation Method 1
the electrical connector has a surface for contacting the electrical component with a frustoconical shaped projection that is able to penetrate a surface coating or corrosion layer on the surface of the electrical component
Data Source
AI summary
An electrical connector is provided as a one-piece, unitary element for providing electrical connection between an electrical cable and an electrical component. The electrical connector has a substantially planar body with a planar first surface and a planar second surface and a central aperture with a dimension to receive a fastener. At least one frustoconical shaped projection extends from the body for contacting and penetrating into an electrical component. A cable terminal is integrally formed with the body and extends radially outward for coupling directly to an electrical cable and provides an electrical connection between the electrical cable and the body. The projection has an axial passage and forms an annular contact surface for mating with the electrical component. The projection can surround the central aperture of the body or can be a plurality of projections spaced outwardly from and uniformly spaced around the central aperture.