Blade Receptacle With Deflection Stops For Vibration Resistance
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Solution Overview
Problem
Existing electrical contact designs, particularly in the automotive industry, face issues with maintaining reliable power transmission under vibrations due to limited contact surface area, spring tongue deflection, and high insertion forces when using materials with low elasticity, leading to potential contact interruptions.
Innovation Solution
A tab sleeve design featuring a box-shaped contact area with integral contact spring tongues and stop mechanisms to limit deflection, combined with embossings and stampings for enhanced stability and force distribution, ensuring secure contact even with low elasticity materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If rounded side walls are used to absorb vibrations, then vibration absorption is improved, but contact surface area is reduced leading to contact interruption
Solution Approach 1:
The contact area is segmented into multiple contact zones (first contact zone on base plate, second contact zones on side walls) with distinct functions. The rounded side walls segment the vibration absorption function while the base plate segments the primary contact function, allowing each segment to specialize without compromising the other.
Solution Approach 2:
The invention adds a third contact zone dimension by placing contact springs on the base plate in addition to the side wall contact zones. This multi-dimensional contact arrangement ensures that even if side wall contacts are compromised by vibration, the base plate contact zones maintain electrical connection.
2Reliability
If spring tongues are cut out to provide elastic contact, then contact reliability under vibration is improved, but insertion forces become excessively high
Solution Approach 1:
The base plate is designed with locally differentiated properties: rigid in most areas to maintain structural integrity and reduce insertion force, but with localized spring elements at specific contact zones to provide necessary elasticity. This local quality differentiation allows the structure to be both stiff and flexible where needed.
Solution Approach 2:
The invention changes the physical state of specific base plate regions by creating spring elements with different mechanical properties (higher elasticity) compared to the rigid base plate. This parameter change allows localized deformation for contact reliability while the overall structure remains stiff for low insertion force.
3Stability of the object's composition
If contact springs are made from low elasticity materials, then structural stability is improved, but the force required to insert contact blade becomes very high
Solution Approach 1:
The base plate is segmented into rigid structural regions and flexible contact regions. The majority of the base plate uses low elasticity material for structural stability, while specific contact zones incorporate spring elements that provide the necessary flexibility for insertion without requiring excessive force.
Solution Approach 2:
The spring elements act as intermediaries between the rigid base plate structure and the contact blade. They mediate the force transmission by providing localized flexibility that reduces insertion force while the rigid base plate maintains overall structural stability.
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 design prevents permanent deformation of contact spring tongues and reduces insertion forces, maintaining reliable electrical contact and secure power transmission under vibrations without compromising the spring property of the material.
Implementation Method 1
the contact spring tongue pointing in the direction of the base plate... vibrations are absorbed by the rounded side walls... spring tongues can bend open when the contact blade is inserted at an angle
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Flat plug sleeve consists of conductor connecting section (2) and socket-shaped contact region (1) for contacting complementary contact blade. Contact region includes specified structure with plate-shaped first contact zone (10), side walls (11,11') and plate-shaped second contact zone (12,12').Side of second contact zone, facing conductor connecting section, locates stop for deflection of sprung contact reed (13).