Connector Assembly Plate Contact Elastic Spring Integration
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Solution Overview
Problem
Existing connector technologies aim to improve connection reliability but often increase the number of components, which is undesirable for simplification and cost reduction.
Innovation Solution
A connector assembly design featuring a plug connector with a plate-shaped contact portion and a receptacle connector with elastic spring pieces formed from a single metallic plate, allowing for multiple contact points while reducing the number of components by integrating the contact and crimping portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple rack-side contacts are used to contact the battery-side contact simultaneously, then connection reliability is improved, but the number of components increases
Solution Approach 1:
The patent combines multiple elastic spring pieces (first elastic spring pieces and second elastic spring pieces) into a single integrated component structure that contacts the plate-shaped contact portion at multiple points simultaneously. This merging approach achieves multiple contact points for improved reliability while reducing the number of separate components compared to using multiple independent contacts.
Solution Approach 2:
The receptacle contact is segmented into multiple elastic spring pieces (first elastic spring pieces and second elastic spring pieces) that are distributed across the plate-shaped contact portion. This segmentation allows multiple contact points to be achieved within a single component, improving connection reliability without proportionally increasing the number of separate components.
2Reliability
If a plate-shaped contact portion parallel to the mating direction is used, then connection reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent changes the orientation parameter of the contact portion from the conventional perpendicular arrangement to a plate-shaped configuration parallel to the mating direction. This parameter change improves connection reliability by ensuring simultaneous contact at multiple points, while the integration with elastic spring pieces simplifies the manufacturing process by reducing the number of separate components that need to be assembled.
3Reliability
If elastic spring pieces are used to contact the contact portion, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple elastic spring pieces (first elastic spring pieces and second elastic spring pieces) into a single integrated receptacle contact component. This merging reduces device complexity by eliminating the need for multiple separate spring components, while still achieving multiple contact points for improved connection reliability.
Solution Approach 2:
The elastic spring pieces serve multiple functions simultaneously: they provide elastic contact force for reliable electrical connection, accommodate misalignment during mating, and distribute contact pressure across multiple points. This multi-functionality improves connection reliability without proportionally increasing device 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 achieves high connection reliability with a reduced number of components, enabling efficient electrical connection while minimizing costs and component complexity.
Implementation Method 1
The receptacle contact includes a pair of first elastic spring pieces that is contactable with the first contact surface
Implementation Method 2
The second contact is formed by bending a single metallic plate
Data Source
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AI summary
A plug contact (6) includes a plate-shaped contact portion (10). The plate-shaped contact portion (10) includes an upper contact surface (10D) where a receptacle contact (8) is contactable. A plug housing (7) includes: a base (22); a pair of side end cover portions (26) that projects in a mating direction from the base (22) and covers both side ends (10B) of the plate-shaped contact portion (10); a leading end cover portion (27) which couples leading ends (26A) of the pair of side end cover portions (26) in the mating direction and covers a leading end (10A) of the plate-shaped contact portion (10); a pair of beams (28) that couples the base (22) with a middle portion (27B) of the leading end cover portion (27) in a longitudinal direction; and an outside cover (24). The receptacle contact (8) includes a pair of upper elastic spring pieces (41) disposed so as to sandwich one of the beams (28). The receptacle contact (8) is formed by bending a single metallic plate (M).