Segmented Contact Pin Receptacle for High-Current Thermal Movement
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Solution Overview
Problem
Existing power contacting devices for printed circuit boards and busbars fail to ensure reliable high-current connections when components move relative to each other due to thermal or mechanical stress, leading to incomplete contact and potential damage.
Innovation Solution
A one-piece contact pin receptacle formed by two movable partial contacts with coaxially arranged openings and bent contact arms that mesh, providing a larger surface area for electron transfer and ensuring secure mechanical connection, allowing for relative movement compensation and cost-effective manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single rigid contact pin receptacle is used, then the mechanical structure is simple, but reliable contact cannot be ensured when components move relative to each other due to thermal or mechanical stress
Solution Approach 1:
The contact pin receptacle is divided into two separate partial contacts (4, 5) that are arranged one above the other. Each partial contact can move independently relative to the contact pin, allowing the system to accommodate relative movements between components while maintaining reliable electrical contact. This segmentation enables each partial contact to compensate for displacement in different directions.
Solution Approach 2:
The partial contacts are designed with elastic properties, allowing them to be deformable rather than rigid. This enables the partial contacts to dynamically adjust their position and maintain contact pressure even when the contact pin shifts due to thermal expansion or mechanical stress, ensuring continuous reliable contact.
2Reliability
If the contact area is increased to ensure reliable high-current connection, then the current carrying capacity is improved, but the device dimensions increase
Solution Approach 1:
Instead of increasing the contact area in a single plane, the invention utilizes the axial dimension by stacking two partial contacts one above the other. This three-dimensional arrangement increases the total contact surface area available for current transfer while maintaining a compact overall device footprint, allowing high current capacity without proportionally increasing device volume.
3Reliability
If multiple contact elements are used to compensate for relative movement, then contact reliability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The two partial contacts are combined into a single one-piece component through stamping and bending operations. This integrated design eliminates the need for separate manufacturing and assembly of multiple discrete contact elements, reducing manufacturing complexity and cost while maintaining the reliability benefits of having multiple contact surfaces.
4Reliability
If the contact arms are bent towards each other to mesh, then the contact surface area is increased for better electron transfer, but the manufacturing precision requirements increase
Solution Approach 1:
The contact arms are designed with elastic properties that allow them to self-adjust and self-align during assembly and operation. The elastic deformation capability enables the contact arms to automatically compensate for minor manufacturing tolerances and achieve proper meshing alignment without requiring extremely tight manufacturing precision, while still providing sufficient contact surface area for efficient electron transfer.
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 solution enables reliable high-performance power contacting even under relative movement, ensuring safe passage of high currents with small dimensions, and provides a durable, cost-effective, and adaptable connection system.
Implementation Method 1
Due to the arms which are provided according to the invention and are bent towards one another in a combing manner, there is always a sufficient surface area available for the electron transfer.
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The invention relates to a device for power contacting (1), comprising a contact-pin receptacle (2) and at least one electrical connector (3), wherein the contact-pin receptacle (2) is integrally formed from two partial contacts (4, 5), which are arranged one over the other at a distance from each other and which can be moved relative to each other, wherein each partial contact (4, 5) has an opening (6, 7) with contact arms (8, 9) protruding into the opening (6, 7), wherein the two openings (6, 7) are arranged coaxial to each other, wherein the contact arms (8, 9) of one opening (6, 7) are bent toward the contact arms (8, 9) of the other opening in such a way that the contact arms mesh with each other.