PCB-to-Coil Contact Spring Support for Brake Solenoid Valves
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Solution Overview
Problem
Existing contacting devices for solenoid valves in vehicle brake systems face challenges in establishing a stable and resilient electrical connection between printed circuit boards and coil bodies with minimal material usage.
Innovation Solution
A contacting device featuring a helically formed, electrically conductive contact spring and a pin that supports the spring, allowing for stable electrical contact between the printed circuit board and coil body, with the pin providing axial and radial support and an optional electrically conductive welding element for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a contact spring is used to establish resilient electrical contact between printed circuit board and coil body, then electrical contact reliability is improved, but device complexity and material usage increase
Solution Approach 1:
The pin is inserted into the interior space of the contact spring, creating a nested structure where the pin is contained within the spring. This nesting eliminates the need for separate housing elements to guide or support the spring, reducing device complexity while maintaining the resilient electrical contact function
Solution Approach 2:
The pin extracts the supporting function from the contact spring itself, concentrating the support function in a separate, minimal element. This allows the contact spring to focus solely on providing resilient electrical contact while the pin provides internal support, reducing overall material usage
2Stability of the object's composition
If additional housing elements are used to support the contact spring, then stability is improved, but material usage and device complexity increase
Solution Approach 1:
The pin is nested within the contact spring's interior space, providing support without requiring external housing elements. This internal nesting achieves stability with minimal material while avoiding the need for additional supporting structures
Solution Approach 2:
The pin serves multiple functions: it supports the contact spring axially, provides lateral guidance, and enables stable electrical contact. This multi-functionality eliminates the need for separate housing elements that would otherwise be required to provide these same functions
3Strength
If soldering processes are used to establish electrical connection, then connection strength is improved, but manufacturing complexity and time increase
Solution Approach 1:
The invention replaces the thermal/soldering process with a mechanical insertion system. The pin is inserted into the contact spring's interior space, creating a mechanically secure connection that eliminates the need for soldering processes, thereby improving manufacturing productivity while maintaining connection strength
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
Enables a stable and resilient electrical connection with reduced material usage, compensating for dimensional deviations and providing a more resistant connection compared to soldering, while eliminating the need for additional housing elements and soldering processes.
Implementation Method 1
The contact spring (115) has been formed in helical and electrically conductive manner and configured to be contacted or capable of being contacted with the printed circuit board (105) at a first spring end (122) and configured to be contacted or capable of being contacted with the coil body (110) at a second spring end (125), situated opposite the first spring end (122), in order to enable a resilient electrical contacting of the printed circuit board (105) with the coil body (110)
Data Source
AI summary
A contacting device for electrical contacting of a printed circuit board with a coil body for a solenoid valve for a brake device for a vehicle, including: a helical electrically conductive contact spring which is configured to be contacted or being contactable with the printed circuit board at a first spring end and configured to be contacted or being contactable with the coil body at a second spring end, situated opposite the first spring end, to enable a resilient electrical contacting of the printed circuit board with the coil body; and a pin which is receivable or has been received in an interior space of the contact spring, the pin being configured to support the contact spring from the interior space in a received state received in the interior space. Also described are a related solenoid valve, method, and computer readable storage medium.