Spring-Arm Electrical Connector for Stable Current Transmission
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Solution Overview
Problem
Existing electrical connection elements with rigid contact elements and mating contact elements suffer from reduced current transmission due to lack of elasticity and contact pressure, and are costly to produce.
Innovation Solution
An electrical connection element with a metal strip design featuring alternating first and second portions bent around a center axis, forming spring-arm shapes that provide elasticity and sufficient contact pressure, allowing for flexible distance adjustment and improved mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If rigid contact elements are used, then structural stability is improved, but current transmission capability deteriorates due to lack of elasticity and contact pressure
Solution Approach 1:
The contact element is segmented into multiple contact blades (at least three) arranged around the central axis, each capable of independent elastic deformation. This segmentation allows each blade to independently apply contact pressure to the mating contact element while maintaining overall structural stability through their coordinated arrangement.
Solution Approach 2:
The contact blades are designed with elastic properties that allow them to dynamically adjust their position and apply contact pressure. The blades can deform elastically under load to ensure reliable electrical contact while returning to their original position when the load is removed, providing both stability and adaptability.
2Reliability
If contact plates with multiple contact blades are used, then current transmission is improved, but production cost deteriorates due to high manufacturing complexity
Solution Approach 1:
Multiple contact blades are merged into a single integral component formed from one piece of electrically conductive material. This unified structure eliminates the need for separate manufacturing and assembly of individual blades, significantly reducing production complexity and cost while maintaining the multi-blade configuration for improved current transmission.
Solution Approach 2:
The single-piece contact element serves multiple functions simultaneously: it provides structural support, electrical conduction, elastic contact pressure, and mechanical stability. This multi-functionality reduces the need for additional components and simplifies the manufacturing process.
3Reliability
If toroidal angular springs are used, then elasticity and contact pressure are improved, but production cost deteriorates
Solution Approach 1:
The contact blades are designed with specific geometric parameters including thickness between 0.1-1.0mm, width between 1-10mm, and length between 5-50mm, with elastic moduli optimized for the intended application. These parameter optimizations allow the blades to provide adequate elasticity and contact pressure using simpler, more cost-effective manufacturing methods compared to toroidal springs.
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
Enhances current transmission with uniform distribution and mechanical stability while reducing production costs through a stamping and bending process.
Implementation Method 1
the first portions and the second portions are each bent around an axis of rotation that runs parallel to the center axis... each first portion and each second portion are each bent so as to contact the contact element... provide elasticity and sufficient contact pressure
Data Source
AI summary
An electrical connection element for electrically connecting a contact element to an associated mating contact element has a metal strip with a first side end S1 and a second side end S2 and a center axis M. First portions are formed alternately along the center axis M at the first side end S1 and second portions are formed alternately at the second side end S2. Each first portion is connected to the two adjacent second portions via a third portion of the metal strip. The first portions and the second portions are each bent about an axis of rotation R1, R2, that runs parallel to the center axis M. The bent first portions are each arranged between the adjacent bent second portions. Each first portion and each second portion are bent to contact the contact element. The third portions are each set up to contact the mating contact element.