Power Contact Torsion Resistance via Locking Tongue
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Solution Overview
Problem
Existing power contacts used in electrical and hybrid vehicles are inadequate for transmitting high electrical powers due to their inability to withstand torsion forces and high voltages, as they are typically designed for smaller applications and lack sufficient locking mechanisms to prevent deformation under mechanical stress.
Innovation Solution
A power contact design featuring a cylindrical spring element with a locking tongue and stop edges, which is mounted coaxially with the contact terminal, providing enhanced resistance to torsion forces and allowing for secure assembly without additional holding elements or welding, enabling the transmission of high currents and voltages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a cylindrical spring element is used to conduct high currents, then the current carrying capacity is improved, but the resistance to torsion forces deteriorates due to lack of intrinsic barrier against relative rotation
Solution Approach 1:
The patent introduces asymmetric locking tongues on the cylindrical spring element that engage with corresponding features on the contact terminal. This asymmetric design prevents relative rotation between the cylindrical components, providing torsion resistance while maintaining the cylindrical shape needed for high current capacity.
Solution Approach 2:
The locking tongues are pre-formed as integral parts of the spring element during manufacturing. This preliminary action ensures that the anti-rotation mechanism is already in place before assembly, preventing torsion forces from deforming the spring element during operation.
2Strength
If additional locking mechanisms are added to prevent relative rotation, then the resistance to torsion forces is improved, but the device complexity increases
Solution Approach 1:
The locking tongues are merged with the spring element as an integral component rather than separate parts. This combining of functions reduces the number of discrete components and simplifies assembly while providing the necessary anti-rotation capability.
Solution Approach 2:
The locking tongues are designed to automatically engage with the contact terminal during assembly without requiring additional fastening operations. The spring element's own geometry provides the locking function, eliminating the need for separate locking mechanisms.
3Strength
If the spring element is made stronger to resist deformation, then the resistance to torsion forces is improved, but the manufacturing cost increases
Solution Approach 1:
The spring element is segmented into functional zones: the locking tongues for anti-rotation, the spring body for electrical conduction and mechanical compliance, and the contact surfaces for electrical connection. This segmentation allows each zone to be optimized independently, maintaining strength where needed while using simpler, cheaper materials and processes where possible.
Solution Approach 2:
The patent optimizes geometric parameters of the locking tongues and spring element geometry to achieve the required strength-to-cost ratio. By carefully selecting dimensions, thickness, and curvature radii, the design achieves sufficient torsion resistance using standard manufacturing processes rather than requiring expensive materials or complex fabrication.
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 effectively prevents relative rotation and linear motion between the contact terminal and spring element, ensuring reliable connection under high torque and bending forces, allowing for the safe transmission of 250 A at up to 600V with a strength of up to 860 N at 1 meter, while being inexpensive and manufacturable from two pieces of sheet metal.
Implementation Method 1
The contact portion may also be at least partially covered by an additional and separate spring element to support the contact portion and improve the electrical and mechanical contact
Implementation Method 2
the spring element comprises at least one locking tongue... The contact terminal comprises at least one stop edge which together with the spring element's locking tongue blocks the relative rotation of the contact terminal and the spring element
Data Source
Figure 1A
Figure 1B
Figure 2A~2B
AI summary
The present invention relates to a power contact comprising a contact terminal (20) and an essentially cylindrical spring element (10), wherein the contact terminal (20) comprises a connection portion (21) for power connection and a contact portion adapted for the reception of a contact pin. The spring element (10) is mountable essentially coaxially with the contact portion. The contact terminal (20) further comprises at least one stop edge (26) and the spring element (10) comprises at least one locking tongue (11) which is bent essentially into a plane perpendicular to the spring element's longitudinal axis providing a corresponding locking edge which together with at least one of the said contact terminal's stop edges (26) blocks a relative rotation of the contact terminal (20) and the spring element (10) with respect to each other.