Cable Connector With Preloaded Resilient Contact Beams
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Solution Overview
Problem
Cable connectors with standard pin configurations face challenges in achieving reliable contact with pin header connectors due to insufficient contact pressure and sensitivity to vibrations, leading to potential disconnection issues, especially in automotive applications.
Innovation Solution
The design incorporates terminal contacts with two parallel resilient contact beams and a third resilient beam that preloads the first two beams, enhancing contact pressure and incorporating a backbone with flanges and additional features like flags and a crimp connection to provide self-alignment, flexibility, and retention mechanisms, reducing vibration sensitivity and facilitating easier assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard pin configurations are used, then the connector structure is simple, but the contact pressure is insufficient leading to unreliable contact
Solution Approach 1:
The third resilient beam applies preliminary action by preloading the first two contact beams before the pin header connector is inserted. This preloading ensures that the contact beams are already under tension and ready to engage with the pins, providing immediate and reliable contact pressure from the moment of insertion, thereby resolving the contradiction between contact reliability and structural simplicity.
Solution Approach 2:
The patent changes the mechanical parameter of the contact beams by introducing a third resilient beam that actively preloads the first two contact beams. This transforms the static contact structure into a dynamically preloaded system, increasing contact pressure and reliability without requiring a complete redesign of the connector architecture.
2Reliability
If rigid contact beams are used, then structural stability is improved, but vibration sensitivity increases leading to disconnection issues
Solution Approach 1:
The patent applies dynamics by using resilient (flexible) contact beams instead of rigid ones. The first two contact beams and the third beam are designed to be elastically deformable, allowing them to absorb and dampen vibration forces. This dynamic flexibility enables the contact beams to maintain stable electrical contact while accommodating vibrational movements, thereby reducing vibration sensitivity and improving connection stability.
Solution Approach 2:
The resilient contact beams provide beforehand cushioning by being pre-loaded and positioned to absorb incoming vibration forces. The elastic nature of the beams creates a cushioning effect that protects the electrical connection from the harmful effects of vibrations, preventing disconnection issues while maintaining structural stability.
3Force
If contact beams are preloaded to maximize contact force, then contact pressure is improved, but the risk of exceeding elastic limits increases
Solution Approach 1:
The patent carefully controls the preload parameter by designing the third resilient beam with specific elastic properties that generate sufficient contact force without exceeding the elastic limits of the first two contact beams. The preload is optimized to maximize contact pressure while maintaining the beams within their elastic deformation range, preventing permanent deformation and ensuring long-term reliability.
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 configuration ensures higher contact pressure, reduces vibration sensitivity, and simplifies assembly, resulting in a more reliable and stable connection between the cable connector and pin header connector, suitable for automotive applications.
Implementation Method 1
two parallel resilient contact beams (44, 45) with tips (47) forced apart by an oppositely directed third resilient contact beam (48)... The third beam preloads the first two contact beams before insertion of a contact pin (6)... resulting in a firm contact pressure with an inserted contact pin (6) of a complementary pin header connector (2)
Data Source
AI summary
A connector, such as a cable connector, with terminal contacts including two parallel resilient contact beams and a third resilient beam. Tips of the two parallel resilient beams are forced apart by the third resilient beam. The third beam can also be a resilient contact beam, e.g., extending into a direction opposite to the direction of the other two contact beams.