Shielding Element Cutting Edge Penetrates Aluminum Oxide
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Solution Overview
Problem
Existing solutions for connecting aluminum surfaces face difficulties due to oxide layers, requiring high contact forces to achieve sufficient contact resistance, necessitating stable elements.
Innovation Solution
A shielding element with protruding contacting tabs featuring sharp cutting edges and elongate through-openings allows for easy penetration of oxide layers with minimal force, enabling low transition resistance and secure contact with aluminum surfaces, allowing higher current flow without the need for robust elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large contact forces are used to achieve sufficient contact resistance, then reliable contact is achieved, but stable and robust elements are required which increases device complexity
Solution Approach 1:
The cutting edge performs preliminary action by penetrating and removing the aluminum oxide layer before the contacting tab establishes electrical contact. This preliminary mechanical action eliminates the barrier to good electrical contact, allowing reliable contact resistance to be achieved without requiring excessively large contact forces or overly robust elements.
Solution Approach 2:
The invention replaces the purely mechanical pressing system with a combined mechanical-cutting and electrical contact system. The cutting edge mechanically removes the oxide barrier, substituting the need for high contact forces with a cutting action that directly exposes conductive aluminum, thereby reducing the mechanical stability requirements of the elements.
2Reliability
If high contact forces are applied to penetrate oxide layers, then electrical contact is achieved, but the required force increases device complexity and element stability
Solution Approach 1:
The high contact force mechanical system is replaced with a cutting system. The cutting edge mechanically removes the oxide layer through a cutting action rather than relying on high contact forces to deform or break through the oxide, thereby achieving electrical contact with reduced force requirements.
Solution Approach 2:
The harmful oxide layer is extracted or removed from the contact interface by the cutting edge. By taking out the barrier material (oxide layer), the system achieves good electrical contact without needing to apply large forces to push through the oxide, thus reducing the required contact force.
3Reliability
If stable elements are used to generate sufficient contact resistance, then reliable contact is achieved, but the element complexity and manufacturing difficulty increase
Solution Approach 1:
The cutting edge performs preliminary action by removing the oxide layer before electrical contact is established. This preliminary mechanical cutting action simplifies the element design because it does not require the element to be overly stable or complex to generate high contact forces, making manufacturing easier while maintaining reliable contact resistance.
4Force
If the contacting tab is provided with a sharp cutting edge, then oxide layer penetration is easier with less force, but the element becomes more complex
Solution Approach 1:
The function of electrical contact and the function of oxide layer penetration are merged into a single contacting tab element. The cutting edge is integrated directly into the contacting tab, combining two functions (cutting and contacting) that were previously separate operations, thereby reducing overall device complexity despite the added feature.
Solution Approach 2:
The contacting tab is given multi-functionality by incorporating a cutting edge, allowing it to both cut through the oxide layer and establish electrical contact in one element. This universal element performs multiple functions, reducing the need for separate components and thereby not significantly increasing device complexity.
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 secure and efficient contact with aluminum surfaces using less stable elements, facilitating higher current flow while reducing the required force and maintaining a low transition resistance.
Implementation Method 1
The sharp cutting edge makes it possible to penetrate the aluminium oxide layers simply and with little exertion of force
Data Source
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AI summary
There is shown a shielding element (1) for a connector for contacting a counter-element (13) made from aluminium, comprising a sheet-shaped section (2), wherein a through-opening (3) is formed in the sheet-shaped section (2) and at least one contacting tab (4) is provided at the through-opening (3), said contacting tab (4) protruding from the shielding element (1), wherein the contacting tab (4) has a protruding sharp cutting edge (6) at a free end (5).A housing assembly (12) comprises at least one shielding element (1) according to any one of Claims 1 to 7, a counter-element (13)and a mounting element (14) that pushes the shielding element (1) onto the contact element (13). With these embodiments, a penetration of aluminium oxide layers is possible with little exertion of force.