One-Piece Contact Terminal for Low-Resistance Power Connections
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Solution Overview
Problem
Existing power supply connections for high currents face challenges such as large, complex multi-part solutions with high contact resistance and alignment issues during assembly, and sleeves made from thin metal sheets are not suitable for transmitting large currents due to material weakening.
Innovation Solution
A one-piece, solid, electrically conductive connection part with a defined contact area protruding like a collar, featuring a through hole for fastening, and a manufacturing process using forming techniques like extrusion or stamping to create a collar-like contact area with a cross-section matching the conductor part, reducing material waste and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple components are assembled to create a connector with a sleeve and contact surfaces, then the connector can be designed to fit beneath the device surface and provide electrical contact, but the contact resistance increases and the device complexity increases
Solution Approach 1:
The patent merges multiple components (conductor part, sleeve, contact surfaces) into a single integrated connection part. The one-piece design eliminates the need for separate sleeves and contact elements, reducing the number of contact surface pairs from multiple to just one, thereby minimizing contact resistance while maintaining the capability to install beneath device surfaces.
Solution Approach 2:
The connection part is designed with functionally segmented regions within a single piece: a conductor part for current transmission, a collar-like contact region for electrical contact, and a through-hole for mechanical fastening. This segmentation allows each function to be optimized while maintaining structural integration.
2Ease of manufacture
If a sleeve is formed from thin sheet metal using a punch, then the manufacturing process is simple, but the material is weakened at the punched edge making it unsuitable for high current transmission
Solution Approach 1:
The patent changes the material parameter from thin sheet metal to solid conductor material with sufficient cross-sectional area. The connection part is formed with a cross-section that is at least as large as the smallest cross-section of the conductor part, ensuring adequate current-carrying capacity and mechanical strength without the weakening effects of punching operations.
Solution Approach 2:
Instead of creating a sleeve by punching and forming thin metal (which weakens the material), the patent uses a solid conductor part that is directly formed into the final shape using extrusion or stamping processes, copying the desired geometry without the material-weakening punching step.
3Reliability
If holes in the device power supply connection and connector are aligned for screw fastening, then the connector can be securely attached, but the assembly process becomes cumbersome
Solution Approach 1:
The connection part includes a through-hole that enables self-alignment and self-fastening capabilities. The through-hole can be used with a screw or other fastening element to securely attach the connector to the device, and the single-piece design with integrated positioning features facilitates easier alignment during assembly compared to multi-component solutions.
4Ease of operation
If electrical contacts are made freely accessible on the device surface, then connection and disconnection is simplified, but the device design becomes less desirable
Solution Approach 1:
The patent transitions the electrical contact from a surface-level feature to a subsurface feature. The collar-like contact region protrudes from the device surface in a controlled manner, allowing electrical contact to be made at a specific depth while maintaining a clean device surface appearance. This dimensional approach enables contacts to be accessible for connection while preserving device aesthetics.
Data Source
Figure 1~1d
Figure 2~2c
Figure 3~3d
AI summary
A one-piece manufactured connector (100) for an electrical power supply connection has at least one contact area formed from a conductor part (102) by deformation. The contact area projects from a surface of the conductor part (102) like a collar and has an electrical contact surface with which the power supply connection can be made. Furthermore, the contact area contains a through-hole extending through the connector (100), via which the connector and the power supply connection can be detachably connected.