Sheet Metal Electrical Connector Ring for Low-Resistance Plug-On Contact
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Solution Overview
Problem
Existing electrical connection elements for sheet metal parts, such as ground bolts and ground nuts, face issues with rotational loosening, alignment complications, and increased resistance due to multiple contact surfaces, especially when used with plug-on cable connection devices, which are prone to corrosion and oxidation.
Innovation Solution
A metallic ring is used to surround the contact region, applying a permanent stress through heating, cooling, or mechanical squeezing to ensure a high-quality electrical contact while minimizing corrosion, using materials like copper or copper alloys with additional conductive coatings for improved conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ground bolts or ground nuts with threads are used to create electrical connections to sheet metal parts, then rotational fixation and alignment are achieved, but the connection requires multiple boundary surfaces which increases resistance losses and contamination risks
Solution Approach 1:
The connection element is divided into functionally distinct sections: a first contact surface for the sheet metal part, a second contact surface for the cable connection device, and an electrical connection region between them. This segmentation allows each surface to be optimized independently, reducing the need for multiple boundary surfaces while maintaining reliable electrical connection.
Solution Approach 2:
The electrical connection region acts as an intermediary between the first and second contact surfaces, providing a direct current-conducting path that minimizes resistance losses. This intermediate region eliminates the need for multiple boundary surfaces by creating a continuous conductive pathway through the connection element itself.
2Object-affected harmful factors
If protective caps or nuts/bolts are used to protect the flange from contamination during painting, then contamination is prevented, but the attachment process becomes more complex requiring additional protective measures
Solution Approach 1:
The connection element's design inherently protects its contact surfaces from contamination during the painting process. The first contact surface is positioned and oriented such that it remains accessible and protected without requiring additional protective caps or complex protective measures, allowing the cable connection device to be directly attached after painting.
3Ease of operation
If plug-on cable connection devices are used instead of threaded elements, then attachment simplicity is improved, but electrical contact quality deteriorates due to corrosion and oxidation
Solution Approach 1:
The connection element incorporates a conductive coating on its contact surfaces, changing the material parameter to prevent corrosion and oxidation. This coating maintains electrical contact quality over time while preserving the simplicity of plug-on attachment, as the coating provides long-term protection without affecting the basic plug-on mechanism.
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 maintains a low contact resistance, high corrosion resistance, and effective electrical contact over time, even in non-grounded sheet metal parts, by reducing the number of contact surfaces and enhancing conductivity through the ring's stress and coating.
Implementation Method 1
The ring can be shrunk onto the contact region by heating the ring and/or by cooling the connection element or can be attached by a mechanical squeezing. On the heating of the ring and/or by cooling the connection element and then cooling or heating it to an environmental temperature, a permanent tensile stress is produced in the ring
Implementation Method 2
a metallic ring surrounds the contact region, closely contacts the contact region by means of a permanent stress produced in the ring, and has an outer surface that forms a contact surface for the cable connection device
Data Source
AI summary
An electrical connection element for a form-fitted or welding attachment to a sheet metal part and for receiving a cable connection device is characterized by a metallic ring that surrounds a contact region and that closely contacts the contact region by means of a permanent ring stress produced in the ring. The ring has an outer surface that forms a contact surface for the cable connection device.