Plug-In Cable End Contour With Contact Lamellae for Large Conductors
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Solution Overview
Problem
Existing methods for connecting large cross-section electrical cables to contact elements are inefficient, costly, and complex, particularly in automotive applications where pluggable connections are required for ease of assembly and service, and copper-based connections are difficult to weld reliably.
Innovation Solution
A method to modify an electrical line by forming a plug-in contour at its end, using press-forming to create a compacted section with flat surfaces and applying a contact strip with resilient lamellae that project from the surface, allowing for a simple and secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connection methods (soldering, welding, crimping) are used to connect large cross-section electrical cables to contact elements, then reliable electrical connection is achieved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The invention divides the connection system into distinct segments: the electrical line with its compacted plug-in section and the contact element with contact lamellae. This segmentation allows each component to be manufactured independently using optimized processes, avoiding the need for complex post-assembly operations like welding or soldering large cables.
Solution Approach 2:
The invention changes the physical parameters of the electrical line by compacting a section to reduce its cross-section and create a flat surface. This parameter change enables the use of simpler pressing connections instead of complex welding or crimping processes required for standard large cross-section cables.
2Reliability
If copper-based connections are used in automotive plug-in connections, then good electrical conductivity is achieved, but welding reliability becomes difficult or impossible
Solution Approach 1:
The invention replaces the thermal-mechanical welding process with a purely mechanical pressing connection. The contact lamellae are pressed against the compacted plug-in section to establish electrical contact, eliminating the welding step entirely and solving the problem of copper welding reliability in automotive applications.
Solution Approach 2:
By compacting the electrical line to create a smaller cross-section with a flat surface, the invention changes the geometric parameters to enable direct mechanical pressing connections. This eliminates the need for welding regardless of the copper content in the materials used.
3Ease of manufacture
If detachable plug contacts are made from materials different from copper or with reduced copper content, then cost and weight are reduced, but connection reliability to copper conductors deteriorates
Solution Approach 1:
The compacted plug-in section acts as an intermediary between the copper conductor and the non-copper or low-copper contact material. This intermediate structure provides a standardized interface that ensures reliable electrical contact regardless of the material composition of either component.
Solution Approach 2:
The invention changes the geometric parameters of the connection interface through compaction, creating a flat surface with reduced cross-section. This geometric standardization ensures reliable mechanical and electrical contact that is independent of material composition, allowing the use of cost-effective non-copper materials.
4Strength
If crimp connections are used to securely connect plug-in contacts to copper conductors, then connection strength is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The invention separates the connection function into the compacted plug-in section and the contact lamellae, allowing for a simpler pressing connection that achieves sufficient strength without complex crimping operations.
Solution Approach 2:
By compacting the electrical line to create a smaller, flat-surfaced plug-in section, the invention changes the geometric parameters to enable simpler pressing connections that provide adequate connection strength without requiring complex crimping tools and processes.
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 efficient, cost-effective, and robust pluggable connections with improved electrical contacting properties and reduced manufacturing complexity, suitable for automotive applications.
Implementation Method 1
a contact strip (contact lamella strip), wherein the contact strip has a plurality of resilient contact lamellae projecting from the contact strip
Implementation Method 2
forming, in particular press-forming, the electrical line at the line end, creating a (preferably compacted) plug-in section with at least one flat surface section
Data Source
AI summary
A cable or electrical line and a method for producing a plug-in contour at a line end of an electrical line, such as a stranded line. The method includes forming, in particular press-forming, the electrical line at the line end while creating a plug-in section with at least one flat surface section at this line end, providing a contact strip, wherein the contact strip has a plurality of resilient contact lamellae projecting from the contact strip, and applying and connecting the contact strip to the surface section.