Multi-arm Contact Lamellae for High-Current Plug-in Connections
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Solution Overview
Problem
High-current plug-in connections in electromobility and hybrid vehicles face challenges in achieving secure contacting with low electrical resistance and high service life, while also accommodating vibrations and temperature fluctuations, often requiring compromises in design.
Innovation Solution
A high-current plug-in connection design featuring a contact sleeve with elongated contact lamellae and an arm structure that provides additional support, allowing for a higher contact force, lower electrical resistance, and improved mechanical stability, while also distributing current paths effectively to reduce localized intensities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact lamellae have thinner cross sections to increase contact points, then contact resistance decreases, but mechanical strength and contact force decrease
Solution Approach 1:
The contact lamella is segmented into multiple arms (first arm, second arm, third arm) that are distributed around the contact pin. This segmentation allows the contact force to be distributed across multiple contact points while maintaining adequate thickness for mechanical strength. Each arm contributes to the overall contact force, resolving the contradiction between needing thin sections for low resistance and thick sections for high force.
Solution Approach 2:
The contact lamella transitions from a simple linear structure to a multi-dimensional arm structure that radiates in different directions around the contact pin. This dimensional change allows the contact force to be applied from multiple directions simultaneously, increasing the effective contact force without requiring increased thickness of individual sections.
2Strength
If contact lamellae have thicker cross sections to increase contact force, then mechanical strength improves, but electrical resistance increases
Solution Approach 1:
By dividing the contact lamella into multiple arms, the electrical current can flow through multiple parallel paths simultaneously. This segmentation creates multiple current channels that reduce the overall electrical resistance while allowing each arm to maintain sufficient thickness for mechanical strength and contact force.
Solution Approach 2:
Multiple arms are merged into a single integrated contact lamella structure that functions as one electrical component. The arms work together to provide both mechanical support and electrical conduction, combining the benefits of distributed contact points with adequate material thickness for strength.
3Reliability
If more contact lamellae are used to increase contact points, then current distribution improves, but device complexity increases
Solution Approach 1:
Each contact lamella is designed with multiple arms that simultaneously serve as both mechanical contact elements and electrical conductors. This multi-functionality allows a smaller number of lamellae to achieve both good current distribution and adequate mechanical contact, reducing the total number of components needed compared to separate mechanical and electrical elements.
Solution Approach 2:
The arms of each contact lamella are arranged in different spatial directions around the contact pin, creating a three-dimensional contact pattern. This spatial arrangement improves current distribution across the contact interface without requiring a proportional increase in the number of lamellae, as each lamella effectively engages multiple contact zones through its multi-directional arms.
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 design achieves lower electrical resistance, higher mechanical stability, and better wear resistance, with improved current distribution and enhanced contact reliability, suitable for high-current applications up to 300 A.
Implementation Method 1
Elastic contact elements, for example in the form of elongated contact lamellae which protrude inwardly from the contact sleeve
Data Source
AI summary
A socket for a high-current plug-in connection is provided, which includes a contact sleeve and a hollow cylindrical contacting system. The contacting system includes a plurality of elongated contact lamellae, is situated in an inner area of the contact sleeve, and is supported with at least a portion of its outer wall on the inner wall. The contact lamellae extend between a first collar and a second collar of the contacting system. The socket includes a contact lamella, in an area between the first collar and second collar, having an arm, via which the contact lamella is additionally connected to a collar of the contacting system in a supporting manner.