Segmented Test Pin Contact Head for Low-Stress Surface Contact
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Solution Overview
Problem
Existing test pins for energy storage devices often cause unwanted lateral forces and mechanical stress due to lateral displacement, leading to potential damage and poor electrical contact quality.
Innovation Solution
A test pin design with axially extending segments and cutting elements that radially widen and narrow to distribute axial force evenly, minimizing lateral forces and reducing mechanical stress, while providing precise and stable electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a test pin with lateral displacement is used to establish electrical contact, then secure electrical contact is achieved, but unwanted lateral forces and mechanical stress are introduced
Solution Approach 1:
The contact head is divided into multiple segments that can move independently. Each segment contains cutting elements that can radially widen to establish contact with the energy storage surface, distributing the contact force across multiple points and eliminating the need for lateral displacement of the entire test pin.
Solution Approach 2:
The cutting elements are designed to dynamically change their radial dimension during the contact process. When axial force is applied, the cutting elements radially widen to penetrate and scratch the surface, then return to their original position, providing adaptive contact without introducing harmful lateral forces.
2Reliability
If cutting elements radially widen to cut the surface, then low contact resistance is achieved, but axial force is required
Solution Approach 1:
The cutting elements utilize elastic deformation to change their radial dimension in response to applied axial force. This parameter change allows the elements to radially widen and cut the surface oxide layer, establishing low-resistance electrical contact, while the elastic nature allows easy return to the original state when force is removed.
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 high-quality electrical contact with low resistance and reduced heating, minimizing mechanical stress on the energy storage device, allowing for efficient charging and testing.
Implementation Method 1
the contact head is configured in such a manner that the cutting elements radially widen and/or narrow when a force, in particular a compression force, acting on the test pin in an axial direction is applied
Data Source
AI summary
The invention relates to a test pin (10) for electrically contacting a contact partner (20), in particular a planar surface (21) of a contact partner, comprising: a substantially sleeve-shaped main body (1); a contact head (3), which is disposed on a contact side (2a) of the main body (1), said contact side being proximate to the contact partner (20), and which has at least two partial segments (5a, 5b, 5c, 5d) extending axially from a base (4) of the contact head (3) ; wherein the partial segments (5a, 5b, 5c, 5d) each have at least one preferably rigid cutting element (6a, 6b, 6c, 6d) for cutting into and/or scratching open a surface of the contact partner (21), the cutting element extending from an end face of the partial segment in question, and the contact head (3) is designed for radial spreading or coming together of the cutting elements (6a, 6b, 6c, 6d) when a force (F) acting on the test pin (10) in the axial direction, in particular a compressive force, is applied.