Stamped End-Contact Element With Support Area for Low-Cost Stability
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Solution Overview
Problem
Existing electrical contact elements, particularly end-contact elements, face challenges in achieving high mechanical stability while being cost-effective for mass production, as they are often designed as solid turned parts, leading to significant material and assembly costs, and are not suitable for end-face contacting.
Innovation Solution
The development of an electrical contact element formed from a stamped and bent part or deep-drawn metal component, featuring a contact area with a support region, which is connected monolithically to provide mechanical stability and reduce material and assembly costs, allowing for efficient production in mass quantities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If end contact elements are designed as solid turned parts, then mechanical stability and durability are improved, but material costs, manufacturing costs, and assembly costs increase significantly
Solution Approach 1:
The contact element is divided into a contact area with end contact surface and a support area, where the support area is formed from a stamped and bent part or deep-drawn metal component. This segmentation allows the contact area to be optimized for electrical contact while the support area provides mechanical stability through efficient metal forming processes, reducing material waste and manufacturing costs compared to solid turned parts.
Solution Approach 2:
The invention changes the manufacturing method from traditional turning processes to stamping, bending, and deep-drawing processes. These parameter changes in the manufacturing approach enable cost-effective mass production while maintaining the necessary mechanical stability through optimized geometric design of the support area.
2Reliability
If end contact elements are designed as solid turned parts, then mechanical stability is improved, but production efficiency for mass production deteriorates
Solution Approach 1:
By segmenting the contact element into contact area and support area formed through stamping and bending processes, the invention enables high-speed mass production suitable for automotive applications, overcoming the low productivity associated with traditional solid turned part manufacturing.
3Reliability
If end contact elements are designed as solid turned parts, then durability is improved, but material costs increase
Solution Approach 1:
The support area is formed from a stamped and bent part or deep-drawn metal component, which uses material more efficiently than solid turned parts. This reduces material waste and cost while maintaining the durability needed for high mating cycles through optimized structural design.
4Ease of manufacture
If contact elements are formed from stamped and bent parts, then manufacturing cost is reduced, but mechanical stability deteriorates
Solution Approach 1:
The contact element features a contact area with end contact surface optimized for electrical contact and a separately formed support area optimized for mechanical stability. The support area's geometric design and material distribution are locally optimized to provide necessary rigidity and durability while enabling cost-effective stamping and bending manufacturing processes.
Data Source
Figure 1~3
Figure 4~7
Figure 8~11
AI summary
The invention relates to an electrical contact element (3) formed from a stamped and bent part or a deep-drawn metal component (1). The electrical contact element (3) has a contact area (6) with an end contact surface (7) designed for electrical and mechanical contact with an electrical mating contact element. The electrical contact element (3) also has a support area (8) arranged on a side of the contact area (6) facing away from the end contact surface (7) and designed to mechanically support the contact area (6). The contact area (6) is integrally connected to the support area (8) via a primary connecting section (9).