Angled Contact Element for Compact Electrical Plug-in Connections
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Solution Overview
Problem
Existing electrical plug-in connections in mechatronic systems, such as those in motor vehicles, face challenges in achieving a compact, flat structure while maintaining a secure and reliable electrical connection with adequate spring force, as conventional fork-type contacts suffer from material stiffening and reduced spring effect due to angled designs.
Innovation Solution
A contact element with two angled arms and a cutout, featuring circular ends and contact projections, generates a spring force through a longitudinally directed cutout, allowing for a secure and compact connection by restoring the arms to their original position when pressed apart, thus ensuring a high spring force and reduced overall height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a fork-type contact element is designed with angled arms to reduce overall height, then the compactness and flat structure are improved, but the spring force and reliability of electrical connection deteriorate due to material stiffening
Solution Approach 1:
The contact element is divided into functionally distinct segments: angled arms for compact positioning, a horizontal connecting part for structural support, and a vertical contact portion for electrical connection. This segmentation allows each part to be optimized independently - the arms can be angled for space savings while the contact portion maintains adequate spring force through its specific geometric design with width and thickness ratios between 2:1 and 5:1
Solution Approach 2:
The contact element transitions from a conventional planar fork-type design to a three-dimensional L-shaped structure with arms extending in different directions. The first arm extends in a first direction from the contact portion, while the second arm extends in a second direction perpendicular to the first direction, enabling compact arrangement in multiple dimensions while preserving functional performance
2Volume of moving object
If the contact element is made compact and flat, then the arrangement space is reduced, but the normal force required for secure connection increases
Solution Approach 1:
Different regions of the contact element are assigned different geometric properties optimized for their specific functions. The arms have a first width and thickness ratio suitable for compact positioning, while the contact portion has a second width and thickness ratio (2:1 to 5:1) specifically designed to generate adequate spring force. This local differentiation allows compact overall dimensions while maintaining sufficient connection force at the critical contact interface
3Volume of moving object
If the arms are arranged at an angle to reduce height, then the flat structure is improved, but the manufacturing complexity increases
Solution Approach 1:
Multiple functional requirements are merged into a single integrated L-shaped contact element structure. The angled arms, connecting part, and contact portion are formed as one piece, combining mechanical support, electrical connection, and compact positioning functions. This integration reduces the number of separate components and assembly steps, making the complex three-dimensional structure manufacturable through conventional processes
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 contact element achieves a secure and continuous electrical connection with a high spring force, maintaining reliability and compactness, suitable for mechatronic systems, while being economical to manufacture and adaptable to various structural properties.
Implementation Method 1
the plug-in connector of the system component can be connected to the contact element in a force-fitting and electrically conductive manner as a result of a spring effect of the contact element
Data Source
AI summary
A contact element for connection of an electrical plug-in connector of electrical or electronic system components to an electronic printed board assembly is provided herein. The contact element has two mutually spaced arms, each having a circular free end. The arms are connected to one another via a contact portion. At one end, the contact element has an extension piece for the electrical connection to the printed board assembly. The contact element has a cutout over its entire length. The cutout is narrowed in the contact portion by contact projections projecting into the cutout. A clamping region for the force-fitting and electrically conductive clamping of the plug-in connector is formed. The arms are arranged at an angle with respect to the contact portion in such a way that they extend in two different planes.