Shape Memory Contact Element for Low-Force Mating and Retention
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Solution Overview
Problem
Existing electrical contact elements face challenges in reliably retaining mating contacts under harsh environmental conditions, such as high temperature fluctuations and strong vibrations, while maintaining low contact resistance and ease of mating.
Innovation Solution
The use of an electrical contact element with at least one elastically deflectable spring element and a section made of shape memory material that changes shape with temperature, allowing for adjustable contact force and reduced insertion force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a high contact force is used to reliably retain the mating contact under harsh environmental conditions, then the reliability is improved, but the insertion force increases making it difficult to insert and remove the mating contact
Solution Approach 1:
The contact element incorporates a shape memory material section that dynamically changes its contact force based on temperature conditions. At low temperatures (during insertion), the material is softer allowing easy insertion. At high temperatures (during operation), the material transforms to provide higher contact force for reliable retention, thus resolving the contradiction between easy insertion and reliable retention.
Solution Approach 2:
The patent changes the physical parameter of the contact element by using shape memory material that alters its mechanical properties (contact force) in response to temperature changes. This allows the contact force to be low during insertion (easy operation) and high during operation (reliable retention), effectively resolving the technical contradiction through parameter transformation.
2Reliability
If a high contact force is used to ensure low contact resistance, then the contact resistance is reduced, but the wear of the contact element and mating contact increases
Solution Approach 1:
The shape memory material changes its contact force parameter based on temperature. During insertion and normal operation at low temperatures, the contact force is lower reducing wear. When temperature rises during operation, the contact force increases to ensure low contact resistance. This dynamic parameter change resolves the contradiction between low contact resistance and reduced wear by applying high contact force only when thermally activated.
Solution Approach 2:
The contact element exhibits periodic transformation between low and high contact force states based on temperature cycles. During cooling phases (insertion, idle), low contact force reduces wear. During heating phases (operation), high contact force ensures low contact resistance. This periodic action pattern resolves the contradiction between maintaining low contact resistance and minimizing wear over the service life.
3Reliability
If a high contact force is used to secure the mating contact under vibrations, then the reliability under vibration is improved, but the insertion force increases
Solution Approach 1:
The shape memory material transforms its mechanical properties based on temperature. During insertion at low temperature, the material remains soft requiring low insertion force. During vibration operation at elevated temperature, the material transforms to provide high contact force that secures the mating contact against vibrations. This temperature-dependent parameter change resolves the contradiction between low insertion force and high retention under vibration.
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 solution enables the contact element to reliably hold a mating contact under difficult conditions, maintain low contact resistance, and facilitate easy mating, while ensuring a secure connection as needed by increasing contact force with rising temperature.
Implementation Method 1
at least one section made of a shape memory material being integrated into the at least one contact element, which can be transformed from a first into a second shape depending on the temperature
Implementation Method 2
at least one elastically deflectable spring element which has at least one contact point for contacting the mating contact and is designed to generate a contact force acting on the mating contact
Data Source
AI summary
An electrical contact element for mating with a mating contact includes at least one elastically deflectable spring element which has at least one contact point for contacting the mating contact and is designed to generate a contact force acting on the mating contact during operation, at least one section made of a shape memory material being integrated into the at least one contact element, which can be transformed from a first into a second shape depending on the temperature, wherein the at least one contact point in the force-free state of the contact element is located in the first shape of the section made of a shape memory material at a first contact position and in the second shape of the section made of a shape memory material at a second contact position. The contact element is able to reliably hold a mating contact even under difficult environmental conditions, to provide a low contact resistance and to be easily mated with the mating contact.