Contact Member Manufacturing TRIZ Cases

A single-pipe 90° elbow terminal lowers contact resistance and heat rise while preventing wrong electrode insertion and preserving 360° rotation.

A segmented connector shield shortens feed pitch and cuts material use while preserving conductive paths for anti-noise shielding.

A coil spring follow-up mechanism pushes terminals along a guide rail for stable automatic feeding, reducing manual handling time and errors.

Through openings and protrusions lock the crimp ferrule against slip and rotation while preserving cable shape and high-frequency electrical performance.

Defined coating surface structures stop coating flow during connector deformation, avoiding sharp edges, chips, and secondary finishing.

An integral busbar end with plug-in retention removes screws, welds, and bolts to cut resistance while improving assembly and serviceability.

Insert injection molding keeps fine pin pitch stable, blocks solder rise, and protects pins from external stress in high-speed connectors.

A multi-portion connector shield shortens feed pitch to cut material use and takt time while preserving load resistance and noise shielding.

A stamped and bent threaded sleeve terminal simplifies external connector attachment in power semiconductor modules while reducing connection complexity and cost.

A two-piece stamped shield terminal improves seating and shielding in right-angle coaxial connectors while keeping RF connector cost low.

A nickel-phosphorus contact coating replaces gold layers in data and power connectors, cutting plating complexity while maintaining stable contact resistance.

A reinforced catch spring supports the fixing section and limits movement, preventing bending failure and stabilizing connector contacts under vibration.

A sealed holding portion with latent heat material and a plug simplifies terminal sealing while absorbing charging heat and limiting temperature rise.

Disconnectable busbar terminal areas create alternate plug patterns, so one sensor housing supports multiple installation angles with fewer molds.

Localized roughened or structured crimp flanks stop edge slippage during crimping, improving sealing and corrosion resistance.

Alternating mount portions on staggered substrate pads let connectors shrink terminal pitch while preserving isolation and stable insertion force.

A thermally expanding intermediate element keeps connector contact force consistent, lowering resistance, localized heating, and arcing.

An asymmetrical C-shaped SMD connector enables automated PCB assembly while preventing reverse thermocouple polarity and reducing manual labor.

An encased IDC blade and opposing cutting blade simplify wire insertion while preserving strength and reliable contact in compact terminals.

Two-stage lead tab bending controls bend position and angle to reduce tab volume, limit stress, and improve secondary battery energy density.

Distinct signal and ground contact geometries improve socket electrical scaling, cutting insertion loss and crosstalk while preserving mechanical integrity.

Friction-held spring tongues clamp a carrier for simpler assembly, flexible material choice, and improved electromagnetic compatibility.

Pressed cable ends with resilient contact lamellae enable direct mating-plug connection for large cross sections with lower assembly cost and space.

Friction-held spring units clasp a carrier to simplify electrical contact assembly, support flexible mounting, and improve EMC shielding.

By bending a flat preform into a 3D nested tab layout, this case cuts conductor plate waste and improves housing assembly workability.

Bent metal grounding members short selected contacts while avoiding others, cutting crosstalk in high-speed connectors with a simpler layout.

A crimped copper core and corrosion-resistant sheath create a low-resistance subsea pin connection while sealing the joint against corrosion.

A fabric sleeve is folded and fastened around a cable to cut friction damage and ease insertion through undulating conduits.

Bent strip sections create elastic contact pressure and larger contact area for high-current connections while lowering manufacturing cost.

Alternating bent strip sections create spring contact pressure for high-current transmission while reducing connector manufacturing cost.

Pre-electroplating plus higher-temperature reflow plating keeps bent and contact parts fully coated, improving salt-fog corrosion resistance.

Alternating bent metal-strip arms add elasticity and contact pressure, improving current transmission while keeping connector production low-cost.

A filament fixed in the hybrid contact press fit secures the label carrier, simplifying wire marking without interfering with bundling.

An elastic inner-conductor joint simplifies RF connector assembly, cutting part count, lowering cost, and reducing mating damage risk.

Crimped copper-aluminum joints cut copper weight and fixture complexity while improving conductivity, corrosion resistance, and assembly automation.

A common base with swappable 90° and 180° terminals cuts inventory, simplifies installation, and maintains stable conductivity.

A busbar edge radius of 0.2 mm or less digs into multi-core conductors, boosting pull-out resistance while limiting damage.

Process grooves in an inward-folded outer conductor enable one-side seam forming, higher tension resistance, and simpler connector stamping.

A retractable probe verifies terminal strip stop position before cutting, preventing terminal damage and improving sectioning accuracy.

Overlapping opposing contacts from separate carriers narrow connector pitch, cut discarded coupling portions, and reduce connector size.