Two-part electrical contact with deformation zone
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Solution Overview
Problem
The existing methods for manufacturing electrical contacts are resource-intensive and costly due to the need for diverse features and materials at different ends of the contacts, leading to increased complexity and potential surface trauma during assembly, which can result in failures like short circuits and surface erosion.
Innovation Solution
A two-part electrical contact system with deformation zones that allow for easy assembly and fixation without surface trauma, enabling the use of different materials and configurations for optimized physical and electrical properties, using guiding features and recesses to facilitate deformation and locking without scratching or gouging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional manufacturing methods are used to create diverse electrical contact features, then different contact portions can be produced, but manufacturing complexity and costs increase significantly
Solution Approach 1:
The electrical contact is divided into two separate parts: a contact portion and a coupling portion. Each part can be manufactured independently using standardized processes, then assembled together. This segmentation allows different contact portions to be produced through simple assembly variations rather than complex manufacturing processes.
Solution Approach 2:
The coupling portion is designed as a universal component that can be assembled with various contact portions. The standardized coupling mechanism enables a single coupling design to work with multiple different contact configurations, reducing the need for specialized manufacturing for each contact type.
2Adaptability or versatility
If coating or inlaying methods are used to add material properties to electrical contacts, then desired electrical and physical properties can be achieved, but manufacturing effort and costs increase
Solution Approach 1:
The electrical contact uses two different materials for the contact portion and coupling portion, each selected for its specific properties. This composite approach achieves the desired electrical and physical properties through material selection rather than adding coatings or inlays, simplifying the manufacturing process.
3Strength
If interference fixation methods are used to assemble two-part electrical contacts, then the parts can be locked together, but surface trauma occurs causing potential failures
Solution Approach 1:
The harmful interference fixation step is removed from the assembly process. Instead, a deformation zone is incorporated into the design that passively locks the parts together through elastic deformation, eliminating the need for forceful interference fitting that causes surface trauma.
Solution Approach 2:
The deformation zone is pre-formed during manufacturing with a specific geometry that enables self-locking. When the coupling portion is inserted, the deformation zone automatically deforms and locks without requiring additional fixation actions, preventing surface damage.
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 approach simplifies the assembly process, reduces manufacturing costs, and enhances the reliability of electrical contacts by avoiding surface trauma and optimizing material properties for specific applications, while maintaining mechanical and electrical engagement.
Implementation Method 1
A force applied in a direction corresponding with an insertion direction causes a deformation zone (20) provided on the first part (5) to deform. This results in the material forming the deformation zone (20) to deform and be caused to flow outwards to occupy the recess (25).
Implementation Method 2
the material forming the deformation zone (20) to deform and be caused to flow outwards to occupy the recess (25)
Data Source
Figure 1A~1D
Figure 2a~2b
Figure 3A~3B
AI summary
The present invention relates to a two-part electrical contact (1) and method of assembly thereof. The electrical contact (1) comprises a first part (5) configured with a first contacting zone that is at least partially inserted into a second part (10) configured with a second contacting zone. The first part (5) is inserted into the second part (10) to fix the first part (5) and the second part (10) together in mechanical and electrical engagement. The second part (10) is configured with at least one opening (15) to receive the first part (5) and at least one recess (25, 58) provided on an internal surface (30) of the at least one opening (15). The recess (25, 58) is capable of receiving displaced electrical contact material from the first part (5). The first part (5) is configured with at least one deformation zone (20, 50) that is capable of being deformed and is configured to at least partially fill the at least one recess (25, 58) when deformed. The at least one deformation zone (20, 50) is configured to undergo deformation by an abutment of the first part (5) with the second part (10). The method of assembly involves fixing the first part (5) and the second part (10) to each other and the surrounding material by moving the first part (5) into abutment with the second part (10) where the first part (5) is at least partially inserted into the second part (10), and then causing a localized bulging (70) of the outer cross sectional dimension of said second part (10) at an at least one location.