Load Connector Spring Contact Stabilization
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Solution Overview
Problem
Load connectors in motor vehicles experience relative movement due to vibrations, leading to friction corrosion and increased contact resistance between metallic spring contacts and flat pins, which can result in power failure and overheating.
Innovation Solution
A load connector design featuring a housing cap with a contour that securely fits the metallic spring contact, eliminating relative movement and wear by providing a form-fitting and force-fitting mechanism, preferably using plastic housing and metal-coated components for efficient current transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metallic spring contact is used to establish force-fitting contact with a flat pin, then electrical current transmission is enabled, but vibrations cause relative movement leading to friction corrosion and increased contact resistance
Solution Approach 1:
The housing cap with contour acts as an intermediary element that secures the spring contact in position, preventing relative movement between the spring contact and housing, thereby eliminating the harmful friction corrosion while maintaining the force-fitting contact function
Solution Approach 2:
The housing is divided into two parts: the main housing and the housing cap. The housing cap with its specific contour is added as a separate component to secure the spring contact, allowing the original force-fitting contact function to be maintained while adding positional stability
2Reliability
If the spring contact is secured with a housing cap with contour, then relative movement is eliminated preventing wear, but device complexity increases
Solution Approach 1:
The housing cap is integrated with the housing to form a complete enclosure, combining the functions of protection and spring contact securing into a unified structure that reduces overall device complexity
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 effectively prevents friction-induced wear and contact resistance issues, ensuring a safe and reliable electrical connection by stabilizing the spring contact within the housing, thus preventing power failures and overheating.
Implementation Method 1
a metallic spring contact is provided for supplying electrical current from a current line, with the spring contact establishing a force-fitting contact with a metallic flat pin
Implementation Method 2
the housing is closed by a housing cap, the inside of which has a contour designed such that the spring contact is form-fittingly secured in the housing by way of the contour
Data Source
AI summary
A load connector is provided for transmitting electrical current, particularly for use in a motor vehicle. The load connector has a housing in which a metallic spring contact is provided for supplying electrical current from a current line. The spring contact establishing a force-fitting contact with a metallic flat pin of a corresponding connection when the load connector is connected to the connection. The load connector is characterized in that its housing is closed by a housing cap, on inner side of which has a contour designed such that the spring contact is form-fittingly secured in the housing by way of the contour.