Universal Contact With Disk-Shaped Connection Area
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Solution Overview
Problem
Conventional contacts for electrical connections in vehicles require multiple designs to accommodate different outlet directions of electrical lines, leading to increased part and tool costs due to limited variability in exit angles, necessitating separate contacts for each application.
Innovation Solution
A contact with a disk-shaped connection area that allows for a wide range of exit angles (e.g., 30°-330°) relative to the main direction, enabling universal use by allowing welding of electrical lines at various angles, and optionally featuring a polygonal edge for welding a compacted stranded conductor, thereby reducing the need for multiple parts and tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional contacts with fixed geometric arrangements are used, then the outlet direction is determined, but multiple contact designs are required for different outlet directions, increasing part and tool costs
Solution Approach 1:
The contact is designed with a universal connection area that can accommodate electrical lines in multiple directions (e.g., 30°-330° range) without requiring different contact designs. This single contact design replaces multiple specialized contacts, reducing part variety and tool costs while maintaining adaptability to different installation situations
2Ease of manufacture
If multiple contact designs are used for different outlet directions, then each application is optimized, but the number of parts and tool costs increase
Solution Approach 1:
A single contact design with a universal connection area covers a wide range of outlet directions (e.g., 300° range), eliminating the need for multiple specialized contact designs. This reduces manufacturing complexity and part inventory while maintaining full adaptability to different installation requirements
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
The solution enables a single contact design to accommodate various installation situations, reducing the number of required parts and tool costs while maintaining mechanical stability and high current-carrying capacity, allowing for flexible and efficient electrical connections.
Implementation Method 1
a line can be welded to the connection area in an electrically conductive manner
Data Source
Figure 1A~1G
Figure 2A~2C
AI summary
A contact with a connection section (201) and a connection area (202) is proposed. The connection area (202) is designed to allow a conductor (105) to be electrically connected to it. The connection area (202) is disc-shaped and allows for a variety of outgoing directions of the electrical conductor with respect to a main direction (107) defined by the longitudinal extent of the connection section (201). A conductor with such a contact is also proposed.