Contact Member Manufacturing TRIZ Cases

A conductive seed layer plus electroplated bulk contact forms charging contacts on non-conductive housings with lower cost and simpler manufacturing.

An oblong male protrusion and matching female projections limit rotation and movement to keep vehicle terminal connections stable.

Etching, seed-layer deposition, and electroplating form reliable contacts on non-conductive housings without slow overmolding and machining.

A TPE pre-mold and insert-molded housing create a waterproof connector without potting, cutting process complexity and cost.

A punched boss on a plate terminal enables direct wire welding with ±0.03 mm accuracy, less material waste, and lower oxidation risk.

A fluorinated oil and surface-treated metal particle coating cuts wear and keeps contact resistance low during repeated sliding at 0.1 N.

A ferrule with through-openings and protrusions improves cable retention while limiting deformation that can degrade RF signal transmission.

Distal dimple contacts on parallel fingers cut insertion friction, protect leads, and simplify socket manufacturing with a one-piece structure.

Rolling a conductive strip into the jack body cuts socket cost while a slender elastic contact improves insertion stability and connection reliability.

A segmented spring structure lets a receptacle terminal deform in X, Y, and Z directions to maintain reliable contact under position deviation.

A slit sleeve soldered portion increases solder wetting and stability in dense PCB contacts while keeping size, weight, and cost low.

Foil stamping followed by centerless grinding forms circumferential electrode contacts with less precious metal waste, lower cost, and faster fabrication.

A sidewall fastened wall snap-fits the cable connector to the PCB, saving board space while maintaining stable electrical contact.

A fluorinated oil and surface-treated metal particle coating keeps contact resistance low while reducing wear during repeated sliding.

Supporting the hoop material at both ends during insert molding keeps fine-pitch connector contacts aligned despite molten resin flow.

An inward-bent opening edge and opposing contact region increase engagement allowance, preventing elastic contact piece displacement and protrusion.

A stamped interposer with crimped motherboard terminals shortens optical signal paths and makes transceiver modules easier to maintain.

Stamped terminals and molded bases create a dense intermediate board connector that shortens signal paths and simplifies transceiver maintenance.

Active braze elements form carbides at the graphite interface, enabling strong, low-resistance silver-graphite to copper joints without extra layers.

A non-welded leaf spring connector preserves thermal runaway venting, lowers contact resistance on rough cells, and fits varying cell lengths.

Staggered bent limbs form a tubular contact that simplifies stamping and forming while improving coupling and shielding in connectors.

An axial outer-terminal extension covers the connection section without radial overlap, enabling a more compact board connector layout.

Two joined punched-bent busbar parts cut waste and tool wear while overmolding protects the motor-inverter connection in an e-axle.

Compliant spring fingers keep blind-mate antenna-to-PCB coaxial links stable despite board irregularities and mechanical stress.

A web between tubular and flange elements blocks longitudinal moisture ingress in cable lugs while avoiding soldering and hot-dip tinning.

A through hole exposes the spring member position, making female terminal assembly checks easier while preserving contact bias on the tab.

A test pin applies an electric field to outer conductor contacts before assembly, exposing conductive debris early to prevent scrap and short circuits.

Segmented terminal units let a board connector vary conductor count to match different counterpart connectors without redesigning the full layout.

Beryllium-free CuNiSi wires in a hyperbolic female contact cut resistance, carry higher current, and avoid CuBe health risks.

A tubular first outer conductor and bendable plate second conductor prevent gaps, improve shielding, and keep connector manufacturing practical.

Two arc-formed flat plates create a high-current female terminal that eases thick-plate bending while lowering conduction resistance and heat buildup.

Slotted silicon strands with embedded metal traces let one connector flex in y- and z-directions, reducing shearing and connection failure.

A bendable terminal clamps a conductive sheet without welding to stabilize battery sampling signals and simplify module assembly.

Cut portions let the contact support flex with the mating shell, reducing fitting friction while maintaining stable shield contact.

Bent securing tabs and a planar base spread pulling and soldering stress, helping glass-mounted terminals resist peeling and cracking.

Localized three-point crimping with non-pressing gaps secures ultra-fine single-wire conductors while preserving flexibility and conductivity.

Embedded PCB edge busbars simplify rectifier board assembly for excited rotors while improving resistance to centrifugal forces.

Two-layer crimp pieces with voids and localized pressing points secure ultra-fine single-wire conductors with stable mechanical and electrical contact.

Slot and protrusion cutting lets short terminal strip ends be spliced into a continuous strip, reducing connector assembly waste.

Solid-lubricant sliding layers cut friction and wear in electrical contacts while keeping contact resistance stable over more mating cycles.

A peripheral shield cage with contact tabs grounds the plug connector module all around to suppress high-frequency electrical and magnetic interference.