Press-fit Connection Assembly for Thin to Thick Conductor Pieces
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Solution Overview
Problem
Connecting thin conductor pieces to thick conductor pieces is challenging due to the risk of damage from existing methods like screw joints, soldering, or welding, and forming reliable connections between conductors made of different materials such as aluminum and copper is difficult.
Innovation Solution
A press-fit connection assembly where a press-fit element with a radial force is used to securely hold a protrusion of the thin conductor piece against the thick conductor piece, eliminating the need for screwing, soldering, or welding, and allowing for a reliable electrical and mechanical connection, especially suitable for conductors made of different materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screw joints are used to connect thin conductor pieces to thick conductor pieces, then mechanical connection is achieved, but the thin conductor piece may get damaged by the screw
Solution Approach 1:
The patent introduces a connector as an intermediary component between the thin conductor piece and thick conductor piece. This connector distributes the mechanical stress across a larger area, preventing concentration of force that would damage the thin conductor piece while still achieving secure mechanical connection.
Solution Approach 2:
The connection system is divided into separate functional components: the thin conductor piece, the connector, and the thick conductor piece. This segmentation allows each component to be optimized for its specific function - the thin conductor for electrical connection, the connector for mechanical strength and stress distribution, and the thick conductor for current carrying capacity.
2Reliability
If soldering or welding is used to connect conductor pieces, then reliable electrical connection is achieved, but high temperature may melt and damage the thin conductor piece
Solution Approach 1:
The patent replaces thermal joining processes (soldering/welding) with a mechanical connection system using a connector. This substitution eliminates the need for high temperature processes that could damage the thin conductor piece while maintaining reliable electrical connection through proper contact pressure and conductive materials.
Solution Approach 2:
The connector acts as an intermediary that provides a controlled interface between conductor pieces without requiring direct thermal or mechanical fusion. This allows for reliable electrical connection through conductive contact while avoiding the harmful effects of high temperature exposure to the thin conductor piece.
3Reliability
If conductors made from different materials (aluminum and copper) are connected using traditional methods, then connection is achieved, but the difficulty of forming a reliable electrical connection is further increased
Solution Approach 1:
The connector serves as an intermediary component that interfaces between dissimilar materials (aluminum and copper conductors). This mediator is designed to be compatible with both materials, providing reliable electrical connection without requiring complex material matching or specialized joining processes for each material combination.
Solution Approach 2:
The connector is designed as a universal component that can connect different material types (aluminum, copper, and their alloys). This multi-functional design simplifies the connection process by using a single connector type for various conductor material combinations, reducing the complexity that would otherwise arise from material-specific connection requirements.
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 press-fit connection provides a safe, reliable, and cost-efficient assembly of connections, reducing the risk of damage to the thin conductor piece and ensuring a strong electrical and mechanical bond, even when conductors are made of different materials.
Implementation Method 1
The press-fit element may in particular generate a radial force directed to the thick conductor piece, in particular against the inner wall of the receptacle
Data Source
Figure 1~2
Figure 3~5
Figure 6~8
AI summary
The invention relates to an assembly (1) for electrically connecting at least one thin conductor piece (5) to a thick conductor piece (3), in particular for a battery management system. In order to improve the electrical and mechanical connection between the conductor pieces (3, 5) and in order to provide a method for facilitating a connection between the pieces (3, 5), it is intended according to the invention that the thick conductor piece (3) comprises at least one receptacle (15) having an inside wall (23), the thin conductor piece (5) comprising at least one protrusion (19) for insertion into the receptacle (15), the assembly (1) further comprising a press-fit element (11) adapted to be inserted into the receptacle (15) with the protrusion (19) being arranged in the receptacle (15) between the press-fit element (11) and the thick conductor piece (3).