Connector Contact Forming Method for Downsizing Without Buckling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connector manufacturing methods face challenges in downsizing connectors while maintaining the necessary interval between contact points and facing portions, as the elastic limit of socket contacts decreases with size reduction, potentially leading to plastic deformation and buckling, which prevents mating with plug contacts.
Innovation Solution
A method involving a housing with a holding portion, movement suppression portion, and allowing portion, where the contact intermediate product is attached and then plastically deformed using a jig to position the tip portion within the allowing portion, hidden by the movement suppression portion, eliminating the need for high elastic limits and preventing buckling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the connector is downsized, then the size of the connector is reduced, but the elastic limit of the contact decreases making plastic deformation more likely
Solution Approach 1:
The invention changes the deformation mode from elastic to plastic by modifying the manufacturing process. A jig is used to apply controlled plastic deformation to the contact intermediate product, forcing the tip portion into the allowing portion. This parameter change in deformation type resolves the contradiction by making the contact's final position independent of its elastic limit, enabling downsizing without buckling risks.
2Manufacturing precision
If resilient deformation is used to attach the contact to the housing, then the contact can be positioned, but the interval between contact point and facing portion becomes narrower than predetermined interval
Solution Approach 1:
The invention performs preliminary plastic deformation using a jig before final assembly. The jig pre-positions the tip portion of the contact intermediate product into the allowing portion, ensuring the correct interval between the contact point and facing portion is established early in the manufacturing process. This preliminary action prevents subsequent positioning errors and maintains precise dimensional relationships.
3Volume of moving object
If the contact is made smaller, then the connector can be downsized, but the contact may buckle and become impossible to mate with the plug contact
Solution Approach 1:
The invention introduces a jig as an intermediary tool during manufacturing that applies controlled plastic deformation to the contact intermediate product. This intermediary action ensures the tip portion is properly positioned in the allowing portion, preventing buckling and ensuring mating reliability. The jig acts as a mediator that transfers the necessary deformation force while maintaining precise control, enabling smaller contact dimensions without sacrificing 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
Enables the production of downsized connectors with regulated movement and prevented buckling, ensuring reliable mating and detachment without requiring resilient deformation of the contact intermediate product.
Implementation Method 1
inserting a jig between the contact point and the facing portion of the held portion and thereby causing plastic deformation of the contact intermediate product to form a contact
Data Source
AI summary
A method for manufacturing a connector comprises providing a housing and a contact intermediate product, making the holding portion of the housing hold a held portion of the contact intermediate product to attach the contact intermediate product to the housing, and inserting a jig between a contact point and the held portion to deform the contact intermediate product plastically and thereby forming a contact. The contact intermediate product does not enter an allowing portion in a state where it is attached to the housing. After the plastically deformation, a tip portion is situated in the allowing portion, and it is hidden by a movement suppression portion at least in part when viewed along an up-down direction.