Asymmetric Contact Element for Compact Plug-in Connections
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Solution Overview
Problem
Existing contact elements, particularly those in the form of contact lamellae, face limitations in geometric dimensioning and material selection for both spring properties and electrical conductivity, leading to inefficiencies in bridging larger gaps and transmitting current with compactness.
Innovation Solution
The contact element is designed with asymmetric web elements that have two clamping feet and triangular contact wings, allowing for increased contact points per unit length with a smaller width, and features a carrier strip with spring arms that act as torsion springs, enabling a more compact and efficient electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If contact clips are designed symmetrically with rear legs for deflection, then the contact element can transmit current, but the width increases and compactness deteriorates
Solution Approach 1:
The contact element employs asymmetric web elements where only the front leg is designed to deflect during plug-in, while the rear leg remains fixed. This asymmetric configuration eliminates the need for a second deflection leg, reducing the overall width of the contact element while maintaining current transmission capability. The asymmetric design allows the contact element to achieve compactness without sacrificing electrical function.
2Ease of manufacture
If web elements are arranged with larger spacing, then each element can be dimensioned optimally, but the number of contact points per unit length decreases
Solution Approach 1:
The web elements are arranged in an overlapping configuration where elements in adjacent rows partially overlap each other in the longitudinal direction. This overlapping arrangement effectively utilizes the longitudinal dimension to increase the density of contact points per unit length, allowing more contact points to be packed into a given area without compromising the dimensional optimization of individual web elements.
3Device complexity
If the contact element uses a single-component design, then the structure is simpler, but geometric dimensioning and material selection are limited
Solution Approach 1:
The contact element is divided into two separate components: a carrier tape that provides mechanical support and spring function, and web elements that provide electrical contact. This segmentation allows each component to be independently optimized - the carrier tape can be designed for mechanical properties while the web elements can be designed for electrical properties and geometric dimensioning, thereby increasing overall design flexibility without significantly increasing structural complexity.
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
This design significantly increases the density of contact points and current transmission while maintaining compactness, allowing for greater tolerance in angular deviations and improved installation options.
Implementation Method 1
the carrier strip for the web elements arranged one behind the other in the longitudinal direction of the carrier strip has in each case two spring arms which branch out transversely from a web extending in the longitudinal direction of the carrier strip and act as torsion springs
Data Source
Figure 1a~1g
Figure 2a~3
Figure 4a~4f
AI summary
A contact element (10) has a longitudinally extending, spring-elastic carrier band (11) and a plurality of web elements (17) arranged one behind the other in the longitudinal direction of the carrier band and spring-loaded to the carrier band (11) perpendicular to the plane of the carrier band for mediating electrical contact between two opposing surfaces. A more compact design is achieved by the fact that the web elements (17) are asymmetrically formed with respect to a central plane (M1) extending in the longitudinal direction of the carrier band.