Critical Comparison of Solid and Flexible Press-Fit Zones Based on Mechanical Parameters

The pursuit of electrification in recent years has accelerated trends like miniaturization and connectivity. This has prompted the electrical connector industry to adopt press-fit zones more extensively in the race for electrification. The utilization of press-fit zones offers several advantages, including simpler assembly, re-usability, and enhanced reliability. In the automotive industry, press-fit zones are widely used in various applications, extending beyond the electrified powertrain and encompassing everyday components such as steering wheels, airbags, and ABS systems. Although hybrid electric vehicles frequently utilize press-fit zones, their usage is not limited to the mundane domains. Among the various press-fit shapes, the most prevalent ones are the solid press-fit zones with a square cross-section and the flexible press-fit zones resembling an eye of a needle (EON). The focus in literature has traditionally been on comparing the electrical aspects of solid and EON zones. However, it is essential to acknowledge that mechanical parameters, such as geometry, material, and manufacturing techniques, play a significant role in influencing the final electrical performance of these press fit zones. These mechanical factors can have a substantial impact on the overall functionality and reliability of the connectors, and therefore should not be overlooked when considering their performance and compatibility for specific applications. After a thorough evaluation, press-fit zones were carefully selected and analyzed based on a range of mechanical parameters. The results obtained from this analysis serve as a fundamental reference for choosing the appropriate zones for specific applications. By considering these mechanical factors, engineers and designers can make informed decisions, ensuring that the selected press-fit zones align perfectly with the requirements and demands of each particular use case. This approach enhances the overall performance, reliability, and efficiency of the connectors in their intended applications.