Press-In Contact Element Assembly for Multi-Level Zone Tolerance

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Solution Overview

Problem

Conventional press-in contact elements with multiple zones at different heights face challenges in maintaining precise layer thicknesses and tolerances due to complex manufacturing processes, leading to increased costs and reduced reliability.

Innovation Solution

A press-in contact element with multiple zones at different heights is produced by forming partial contact elements with galvanic coatings, then aligned using a connection interface with complementary contour profiles, ensuring precise positioning and uniform coating thickness through a method involving punching, laser processing, and galvanic coating on a continuous strip, followed by a form-locking or material connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If press-in zones are positioned at different heights to contact multiple circuit carriers, then the functionality of connecting multiple circuit carriers is improved, but the manufacturing complexity and cost increase due to complex bending processes

Engineering Contradiction:

Improveability to contact multiple circuit carriersVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The press-in contact element is divided into multiple press-in zones positioned at different heights along the edge contour, each zone capable of independently contacting a separate circuit carrier. This segmentation allows the single component to fulfill multiple connection functions without requiring complex assembly processes

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The press-in zones are arranged in the vertical dimension (different heights) along the edge contour, transitioning from a single-plane arrangement to a multi-level three-dimensional configuration. This dimensional change enables contact with multiple circuit carriers stacked vertically while maintaining a simple planar manufacturing process

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Adaptability or versatility

If press-in zones are positioned at different heights, then multiple circuit carriers can be contacted, but the layer thickness tolerance of galvanic coating cannot be guaranteed

Engineering Contradiction:

Improvemulti-level contact capabilityVSAvoidgalvanic coating layer thickness tolerance

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The galvanic coating is applied to the entire press-in contact element before the pressing operation, ensuring that all press-in zones receive a uniform coating layer. This preliminary coating action eliminates the need for complex multi-layer coating processes that would be required if zones were coated separately at different heights

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The galvanic coating is applied uniformly across all press-in zones in a single coating process, ensuring homogeneous layer thickness throughout the element. This approach guarantees consistent coating quality across all zones without requiring separate coating operations for each height level

Inventive Principle:

Principle #33Homogeneity

3Manufacturing precision

If complex bending processes are used to achieve correct height positioning, then press-in zones can be brought to correct heights, but position tolerance and cost are adversely affected

Engineering Contradiction:

Improvepress-in zone height positioningVSAvoidmanufacturing cost and simplicity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The heights of the press-in zones are determined during the punching process by varying the depth of punching at different locations along the edge contour, rather than using complex bending operations. This parameter change in the manufacturing process simplifies production while maintaining precise height positioning

Inventive Principle:

Principle #35Parameter changes

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

This approach allows for high-precision manufacturing with minimized tolerances and reduced costs, ensuring consistent press-in conditions and enhanced reliability by maintaining uniform coating thickness and alignment across all zones.

Implementation Method 1

The press-in pins in the region of the press-in zone therefore have a coating that is made of a suitable material and has a tolerated outer dimension. The coating is applied by means of a galvanic process

Methodology Applied

Scientific EffectGalvanic coating: Electroplating

Data Source

PatentUS20260039041A1Connection arrangement and method for forming a connection arrangement

Publication Date: 2026.02.05 ROBERT BOSCH GMBH

AI summary

A press-in contact element. The press-in contact element includes at least two press-in zones which are each formed at the end of an edge contour of the press-in contact element along respectively parallel extending and spaced apart press-in axes. The at least two press-in zones also have a galvanic coating and a spacing distance from one another in the direction of the press-in axes. In each case then, at least two press-in zones are formed on partial contact elements that are connected to one another in a connection interface to form the press-in contact element.