Switching Device Connection Section With Separated Fastening and Conduction

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Solution Overview

Problem

Electrical switching devices for high-voltage automotive applications face challenges in weight, space, safety, and cost efficiency, as existing solutions do not adequately address the specific requirements of electromobility, such as high switching cycles and electrical safety.

Innovation Solution

The design includes a connection section with a fastening element for mechanical strength and a conductive contacting element for electrical conductivity, where the fastening element is optimized for mechanical requirements without the need for expensive conductive materials, and the contacting element is designed for efficient current conduction, allowing for a lightweight, compact, and cost-effective solution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single integrated element is used for both fastening and electrical conduction, then structural simplicity is improved, but weight and material cost increase due to requiring expensive conductive materials throughout

Engineering Contradiction:

Improvestructural simplicityVSAvoidweight

Core Design Contradiction:

Device complexityVSWeight of moving object

Solution Approach 1:

The connection element is divided into two distinct functional elements: a fastening element for mechanical connection and a contacting element for electrical conduction. This segmentation allows each element to be optimized for its specific function, using appropriate materials without requiring expensive conductive materials throughout the entire structure, thereby reducing overall weight and material cost while maintaining structural and electrical performance

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the connection structure are assigned different material properties: the fastening element uses materials optimized for mechanical strength, while the contacting element uses materials optimized for electrical conductivity. This local differentiation of material quality allows weight reduction in non-conductive areas while maintaining necessary electrical performance in conductive areas

Inventive Principle:

Principle #3Local quality

2Reliability

If expensive highly conductive materials are used throughout the connection structure, then electrical conductivity is improved, but production cost increases

Engineering Contradiction:

Improveelectrical conductivityVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The connection structure is segmented into fastening and contacting elements, allowing expensive highly conductive materials to be used only in the contacting element where electrical performance is critical, while the fastening element uses more cost-effective materials, thereby reducing overall production cost while maintaining necessary electrical conductivity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Highly conductive materials are applied locally only to the contacting element rather than throughout the entire connection structure, optimizing electrical conductivity in the critical current-carrying region while reducing material costs in non-conductive or mechanically-focused regions

Inventive Principle:

Principle #3Local quality

3Strength

If the fastening element is optimized for mechanical strength, then connection reliability is improved, but electrical conductivity deteriorates if conventional conductive materials are not used

Engineering Contradiction:

Improvemechanical strengthVSAvoidelectrical conductivity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The connection function is segmented between a fastening element optimized for mechanical strength and a contacting element optimized for electrical conductivity, eliminating the need for the fastening element to compromise between these conflicting requirements while ensuring the contacting element provides necessary electrical performance

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The contacting element serves multiple functions: it provides electrical conduction and mechanically connects the fastening element to the current-carrying component, while the fastening element focuses on mechanical connection. This functional distribution allows each element to be optimized for its primary role

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 configuration reduces weight, space requirements, and production costs while ensuring electrical safety and high switching performance, meeting the unique demands of automotive applications.

Implementation Method 1

an electrically conductive contacting element extending from the fastening element to the contact point of the current-carrying element

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS11742164B2Electrical switching device, especially a contactor or a relay, with a contacting element and a fastening element

Publication Date: 2023.08.29 TE CONNECTIVITY GERMANY GMBH

AI summary

An electrical switching device includes a connection section for fastening and contacting an electrical conductor. The connection section has a fastening element for fastening the electrical conductor, a current-carrying element spaced apart from the fastening element and including a contact point, and an electrically conductive contacting element extending from the fastening element to the contact point of the current-carrying element and into an inner section of the electrical switching device.