Ground Contact Unit With Flexible PCB Bridges Under Mechanical Load
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Solution Overview
Problem
Existing ground contact units for vehicle battery charging systems face challenges in maintaining electrical connections intact under significant mechanical loads, requiring robust construction to ensure long-term functionality and safety.
Innovation Solution
The use of flexible, spring-deflectable contact bridges that connect the printed circuit board to the outer wall contacts, allowing for elastic deformation under load without compromising fatigue strength, along with secure fastening methods like wire bonding or welding, and a suspended printed circuit board configuration to reduce stress and enhance long-term stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the ground contact unit is constructed to be robust to withstand heavy mechanical loads, then the structural strength is improved, but the electrical connections may still fail due to stress concentration at rigid connection points
Solution Approach 1:
The patent changes the mechanical parameter of the electrical connection from rigid to flexible by using spring-deflectable contact bridges. These contact bridges can elastically deform under mechanical load, changing the stress distribution pattern and preventing stress concentration at fixed connection points, thereby maintaining electrical connection reliability while the outer wall remains structurally robust.
Solution Approach 2:
The patent introduces dynamic capability to the electrical connection system through spring-deflectable contact bridges that can adapt their position and stress distribution in response to varying mechanical loads. This dynamic behavior allows the connection to maintain integrity under changing conditions, resolving the contradiction between robust structural design and reliable electrical connections.
2Stability of the object's composition
If the outer wall is made rigid to provide stable mounting for contacts, then the structural stability is improved, but the fatigue strength of electrical lines deteriorates under repeated loading
Solution Approach 1:
The patent segments the electrical connection system into two functional parts: a rigid outer wall for structural stability and mounting, and flexible spring-deflectable contact bridges for stress absorption. This segmentation allows each component to optimize its function - the outer wall provides stable mounting while the contact bridges handle mechanical stress through elastic deformation, improving fatigue strength without compromising structural stability.
3Ease of manufacture
If traditional soldering methods are used to connect pins to the printed circuit board, then the manufacturing simplicity is improved, but the connection reliability under mechanical load deteriorates
Solution Approach 1:
The patent changes the mechanical parameter of the connection from rigid (traditional soldering) to flexible (spring-deflectable design). The spring-deflectable contact bridges are soldered to the printed circuit board using traditional methods, maintaining manufacturing simplicity, but the spring mechanism itself provides flexibility and stress relief, significantly improving connection reliability under mechanical load.
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 ensures the electrical connections remain intact and functional under heavy mechanical loads, providing improved durability and reliability of the ground contact unit while allowing for automated manufacturing and reduced cycle time.
Implementation Method 1
The lines are formed, at least in sections, by flexible, freely extending contact bridges which are configured to be spring-deflectable toward the base. The flexible, freely extending contact bridges in the line routing between the respective contact on the outer wall and the printed circuit board allow the outer wall to yield somewhat elastically itself when subjected to a load
Data Source
AI summary
A ground contact unit for a vehicle battery charging system, having a ground-side base and an upper outer wall, wherein a receiving space in which at least one printed circuit board is positioned is formed between the base and the outer wall, and having a plurality of contacts provided on the outside of the outer wall for contacting vehicle-side mating contacts, the contacts being electrically conductively connected to the printed circuit board by means of electrical lines, wherein the lines are formed, at least in sections, by flexible, freely extending contact bridges which are configured to undergo a spring deflection toward the base.