Compliant Pin with Independent Resilient Sections for High Density

Solution Overview

Problem

Solderless press-fit electrical contacts face reduced retention force as contact sizes decrease, necessitating a compliant section that generates sufficient retention force regardless of contact or hole size.

Innovation Solution

An electrical contact with a compliant portion featuring resilient engagement and contacting sections that deform independently to generate combined retention forces upon insertion, enhancing retention force without damaging the substrate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the size of contacts and plated through-holes is reduced to accommodate higher contact density, then contact density increases, but retention force decreases below minimum requirements

Engineering Contradiction:

Improvecontact densityVSAvoidretention force

Core Design Contradiction:

ProductivityVSForce

Solution Approach 1:

The compliant portion is divided into multiple independent resilient contact sections (first resilient contact section, second resilient contact section, etc.) that each contribute to retention force. This segmentation allows the total retention force to be distributed across multiple deformation zones, maintaining sufficient holding power even in smaller contacts with reduced thickness

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different sections of the compliant portion are designed with varying local properties - the resilient contact sections have specific thicknesses and geometries optimized for deformation, while the engagement section provides structural support. This local differentiation enables each section to contribute optimally to retention force generation

Inventive Principle:

Principle #3Local quality

2Volume of moving object

If thinner sheet metal is used to reduce contact size, then contact size decreases for higher density, but retention force is reduced

Engineering Contradiction:

Improvecontact sizeVSAvoidretention force

Core Design Contradiction:

Volume of moving objectVSForce

Solution Approach 1:

The compliant portion is divided into multiple independent resilient contact sections (first resilient contact section, second resilient contact section, etc.) that each contribute to retention force. This segmentation allows the total retention force to be distributed across multiple deformation zones, maintaining sufficient holding power even in smaller contacts with reduced thickness

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The resilient contact sections are configured to deform in multiple directions and planes within the plated through-hole. The independent deformation of each section creates a three-dimensional engagement pattern that maximizes retention force from the available thin material

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Force

If resilient contact sections are configured to move independently upon insertion, then retention force is enhanced through combined deformation, but device complexity increases

Engineering Contradiction:

Improveretention forceVSAvoidcompliant section structure

Core Design Contradiction:

ForceVSDevice complexity

Solution Approach 1:

The compliant portion is divided into multiple independent resilient contact sections (first resilient contact section, second resilient contact section, etc.) that each contribute to retention force. This segmentation allows the total retention force to be distributed across multiple deformation zones, maintaining sufficient holding power even in smaller contacts with reduced thickness

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple resilient contact sections are merged into a single integrated compliant portion that functions as one unit during insertion. The sections work together synergistically, with each section's independent deformation contributing to the overall retention force, achieving enhanced performance without proportionally increasing complexity

Inventive Principle:

Principle #5Merging (Combining)

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 solution provides significantly increased retention force compared to traditional compliant pins, ensuring secure connections even in small contacts and holes, minimizing the risk of damage and maintaining stability in harsh environments.

Implementation Method 1

Each of the resilient engagement sections and the resilient contacting sections is deformed and generate independent retention forces which are combined to generate the total retention force of the compliant portion

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

Outer surfaces of the beams form a frictional engagement (e.g., interference fit) with the plated through-hole

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS10230184B1Compliant pin with an engagement section

Publication Date: 2019.03.12 TE CONNECTIVITY SOLUTIONS GMBH

AI summary

An electrical contact for insertion into a hole of a substrate. The electrical contact includes a compliant portion having an opening extending between contact arms. At least one contact arm of the contact arms has a resilient engagement section which extends into the opening of the compliant portion and resilient contacting sections which extend from the engagement section in a direction away from the opening. Upon insertion of the compliant portion into the hole of the substrate, the resilient engagement section of the at least one contact arm engages an opposed contact arm of the contact arms, causing each of the resilient contacting sections to move independently of the resilient engagement section and other resilient contacting sections. Each of the resilient engagement section and the resilient contacting sections are deformed and generate independent retention forces which are combined to generate the total retention force of the compliant portion.