Two-Part Pin-Contact Assembly With Backup Locking Reliability
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Solution Overview
Problem
Existing electrical pin-contact assemblies in the automotive sector face challenges in ensuring reliable and cost-effective connections, particularly in mechanically loaded, warm, and chemically aggressive environments, where primary locking mechanisms can fail, leading to electrical contact failures.
Innovation Solution
A two-part electrical pin-contact assembly is designed with both primary and secondary locking mechanisms, where the primary locking is a materially bonded connection (such as welding) and the secondary locking is a mechanical seating connection, ensuring the pin-contact device is securely locked in the contact body, even if the primary locking fails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a primary locking mechanism (materially bonded connection) is used to secure the pin-contact device in the contact body, then the electrical connection reliability is improved, but the risk of complete failure in harsh environments increases due to single-point failure
Solution Approach 1:
The patent implements a secondary locking mechanism (mechanical seating connection) that acts as a backup in case the primary locking (material bond) fails. This beforehand cushioning approach ensures that if the primary connection deteriorates due to thermal cycling, vibration, or chemical exposure, the secondary mechanical locking prevents complete disconnection, thereby maintaining electrical connection reliability without requiring a fundamentally complex redesign
Solution Approach 2:
The patent applies different locking mechanisms at different locations/levels: the primary locking uses material bonding (welding/soldering) for strong initial attachment, while the secondary locking uses mechanical seating connection for backup support. This local differentiation of locking qualities allows each mechanism to optimize its function while together they resolve the contradiction between reliability and complexity
2Ease of manufacture
If a single primary locking mechanism is used to reduce device complexity, then manufacturing cost is reduced, but the durability in mechanically loaded and chemically aggressive environments deteriorates
Solution Approach 1:
The secondary locking mechanism serves as a pre-planned backup that activates when the primary locking deteriorates over time in harsh automotive environments. This approach extends the duration of action by ensuring that even after prolonged exposure to thermal cycling, vibration, and chemical aggression, the connection remains intact through the secondary mechanical seating connection
Solution Approach 2:
The patent combines two different locking approaches (material bonding and mechanical seating) into a composite locking system. This composite structure leverages the strengths of both methods: the strong initial bond of material bonding and the mechanical reliability of seating connections, thereby extending durability without proportionally increasing manufacturing complexity
3Strength
If a materially bonded connection (welding) is used for primary locking, then the strength of the connection is improved, but the vulnerability to complete failure in case of bond deterioration increases
Solution Approach 1:
The mechanical seating connection is designed as a backup that engages when the material bond deteriorates. This beforehand cushioning ensures that even though the primary welded connection provides strong initial attachment, the system maintains reliability by having a secondary mechanical support that prevents catastrophic failure
Solution Approach 2:
The locking function is segmented into two independent mechanisms: primary locking through material bonding and secondary locking through mechanical seating. This segmentation allows each mechanism to be optimized for its specific function while providing redundancy, resolving the contradiction between strength and failure resistance
Data Source
AI summary
A two-part electrical pin-contact assembly, in particular a nano or pico pin-contact assembly for an electrical plug connection in the automotive sector, is provided. The two-part electrical pin-contact assembly includes a pin-contact device extending in a longitudinal direction and a contact body extending in the longitudinal direction. The pin-contact device is secured in the contact body by a primary locking and a secondary locking.