Sleeve Contact Element with Structured Surface for Insulated Wire Connection
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Solution Overview
Problem
Existing methods for electrically contacting wires, particularly those with insulation layers, face challenges in establishing reliable connections without damaging the insulation and ensuring secure connections, especially when multiple wires are involved.
Innovation Solution
The use of sleeve-shaped contact elements with structured surfaces, featuring elevations such as sharp edges or points, allows for non-positive and secure electrical connections through the insulation layer, enabling the connection of wires with enamel or plastic insulation without removing the insulation, and employing multiple contact elements with varying diameters for multi-layer wire connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional smooth contact elements are used to connect wires, then the assembly process is simple, but the insulation layer of wires cannot be effectively penetrated to establish reliable electrical contact
Solution Approach 1:
The contact element features a structured surface with localized elevations (protrusions, points, or edges) distributed across its contact surface. These elevations concentrate the electromagnetic pulse energy at specific points, enabling effective penetration of the wire insulation layer while the rest of the surface maintains a smooth configuration for simple assembly. This local structural variation resolves the contradiction by providing both reliable electrical contact through insulation penetration and ease of manufacture through overall structural simplicity.
Solution Approach 2:
The structured surface with elevations is pre-formed on the contact element before the connection process. When the electromagnetic pulse is applied, these pre-positioned elevations automatically concentrate energy to penetrate the insulation layer, eliminating the need for complex manual insulation removal or complex connection procedures. This preliminary structural preparation enables reliable electrical contact while maintaining manufacturing simplicity.
2Productivity
If multiple wires with insulation layers are connected simultaneously in an annular gap, then productivity increases, but reliable electrical contact with all wires becomes difficult to achieve
Solution Approach 1:
The contact element's surface is segmented into multiple discrete elevations (protrusions, points, or edges) distributed across the annular contact surface. Each elevation independently targets and penetrates the insulation layer of a specific wire, enabling simultaneous reliable contact with multiple wires arranged in the annular gap. This segmentation allows high productivity through parallel connection while maintaining individual contact reliability for each wire.
Solution Approach 2:
The contact element utilizes the radial dimension of the annular gap to arrange multiple elevations at different angular positions, enabling simultaneous contact with multiple wires radiating from the center. By distributing elevations across the annular surface area rather than concentrating them at a single point, the system achieves both high productivity (multiple wires connected simultaneously) and reliable electrical contact (each wire receives sufficient energy concentration).
3Reliability
If the contact element has high mechanical strength to penetrate insulation layers, then reliable electrical contact is achieved, but the risk of damaging wires increases
Solution Approach 1:
The contact element combines a structured surface with localized elevations that concentrate electromagnetic pulse energy for effective insulation penetration, while the overall structure maintains controlled mechanical properties. The elevations are designed with specific geometry (sharp points, edges, or protrusions) that enable reliable electrical contact through the insulation layer without excessive force that could damage the wire conductor, thus resolving the contradiction between contact reliability and wire damage prevention.
4Ease of manufacture
If wires are arranged with play relative to the sleeve-shaped element, then assembly is simplified, but precise positioning and secure connection are compromised
Solution Approach 1:
The structured surface with elevations creates localized contact points that provide secure mechanical and electrical connection, while the overall sleeve-shaped element maintains a loose fit with play relative to the wire bundle. This allows simplified assembly where wires can be easily inserted, while the elevations ensure precise positioning and secure connection at the contact interface by penetrating the insulation and engaging the conductor.
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 method provides reliable and secure electrical connections for wires with insulation layers, ensuring that the insulation is not damaged during the connection process, and allows for the connection of multiple layers of wires with enhanced mechanical strength and ease of assembly.
Implementation Method 1
a sleeve-shaped connecting element which is deformed by the action of an electromagnetic pulse
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
The method involves electrically contacting a wire (1) in a connection region (2). An electrically conductive sleeve-shaped contact element (15) is provided in active connection with the wire in a contact region (16). An electromagnetic pulse (3) is introduced into the wire in the contact region. A frictional or metallurgical connection is formed between the wire and the contact element. The wire is provided with an insulation layer i.e. paint layer, in the connection region. The insulation layer is destructed when forming the electrical interconnection of a structured surface.