Electrical Connection Assembly Using Spring Section Press-Fit
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Solution Overview
Problem
Existing electrical connection methods, such as soldering and PCB-based solutions, are complex, costly, and expose conductors to heat, while also limiting design flexibility and tolerating only minor deviations in conductor size, leading to high electrical resistance.
Innovation Solution
A press-fit connection between a strip-like lead frame and a conductor with a spring section, where the spring section is elastically compressed in an oval hole, allowing for a low-resistance, non-orthogonal connection with only two parts, avoiding heat exposure and enabling design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering or welding is used to connect two metal parts, then a reliable and non-detachable connection is achieved, but the process requires two steps (connecting and welding/soldering), produces high temperatures, and is complicated and expensive
Solution Approach 1:
The invention extracts the harmful thermal process (soldering/welding) from the connection process, replacing it with a purely mechanical press-fit method. The spring section provides sufficient contact force without requiring thermal bonding, thus eliminating the need for second-step welding while maintaining connection reliability.
Solution Approach 2:
The invention replaces the thermal-mechanical connection system (soldering/welding) with a purely mechanical spring-based press-fit system. The spring section's elastic force substitutes for the thermal bonding process, achieving reliable electrical contact through mechanical means alone.
2Reliability
If soldering with lead-free solders is used, then a non-detachable connection is achieved, but high temperatures are produced which are complicated and expensive and expose the conductors to potentially damaging heat
Solution Approach 1:
The invention converts the potential harm of heat exposure into a benefit by completely avoiding thermal processes. The spring section's elastic properties provide the necessary contact force without any heat generation, protecting conductors from thermal damage while ensuring permanent connection through mechanical interlocking.
Solution Approach 2:
The thermal bonding process is replaced with a mechanical spring-based system. The spring section provides continuous contact force through elastic deformation, achieving permanent connection without exposing conductors to damaging temperatures.
3Ease of manufacture
If a press-fit connection with a cylindrical pin and a hole with limited elasticity is used, then a connection is achieved, but only minor deviations in the size of the pin and/or the hole are tolerated as the electrical resistance will increase if the deviations are big
Solution Approach 1:
The invention introduces dynamic elasticity through the spring section, which can adapt its compression level to accommodate variations in hole size and pin dimensions. This dynamic adjustment maintains optimal contact pressure and low electrical resistance even when manufacturing tolerances vary, unlike rigid cylindrical connections.
Solution Approach 2:
The spring section's elastic properties allow the connection parameters (contact pressure, compression level) to change adaptively based on the actual fit between pin and hole. This parameter flexibility compensates for manufacturing deviations, maintaining low resistance across a wider tolerance range.
4Reliability
If a PCB-based solution with a sleeve embedded in an insulating substrate is used, then an electrical connection is achieved, but three parts (pin, sleeve, and substrate) are necessary which makes the assembly complicated and limits the design
Solution Approach 1:
The invention merges the pin and the support structure into a single integrated spring section. The spring section itself provides both the electrical connection function and the mechanical support, eliminating the need for separate sleeve and substrate components while maintaining connection stability.
Solution Approach 2:
The spring section serves multiple functions simultaneously: it provides electrical conduction, mechanical support, elastic compliance for tolerance compensation, and contact force generation. This multi-functionality replaces the specialized roles of pin, sleeve, and substrate with a single universal component.
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 reduces manufacturing costs, eliminates the need for additional components, and provides a reliable, low-resistance connection that tolerates size deviations, while allowing for non-orthogonal orientations and increased current capacity.
Implementation Method 1
the spring section of the second conductor is elastically compressed in a diameter direction of the hole of the first conductor
Data Source
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AI summary
The invention relates to an electrical connection assembly (1) and an electrical element (20) comprising an electrical connection assembly (1). Prior methods of making an electrical connection between two conductors either require a third element, expose the two conductors to heat or are not reliable. The invention overcomes these disadvantages by using a first conductor (2) having a hole (4) into which a second conductor (3) with an elastic spring section (5) is inserted.