Connector Contact Lance Extension for Wire Snag Prevention
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Solution Overview
Problem
Existing contact structures with lances in connectors suffer from low material yield and deformation issues due to electric wires getting under the lance, limiting the number of contacts that can be produced per unit area.
Innovation Solution
A contact design featuring a lance that extends continuously rearward from the upper wall with an integrated extension piece folded under the rear end upper wall, preventing electric wires from getting under the lance and improving yield by allowing the lance to be caught securely in the housing, thus preventing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the lance is formed by rearwardly folding back a beam that extends forward from an upper wall of the contact, then deformation of the lance is reduced, but yield of material contacts is low and only a small number of contacts can be produced per unit area
Solution Approach 1:
The contact structure is divided into multiple walls (front end upper wall, rear end upper wall, side walls) with the lance extending from a specific wall. This segmentation allows optimization of each component's function while improving overall material utilization and contact yield per unit area.
Solution Approach 2:
The lance extends rearwardly from the front end upper wall in a continuous manner, utilizing the longitudinal dimension of the contact structure. This dimensional arrangement prevents wires from approaching the lance from below while optimizing material layout for higher production yield.
2Reliability
If the lance has a cantilever form with the free end at the rear, then the engaging portion can abut against the connector housing for pull-out prevention, but electric wires easily get under the lance from the free end causing snagging and deformation
Solution Approach 1:
The harmful space underneath the lance is eliminated by extending the lance continuously from the front end upper wall to the rear end, removing the gap where wires could be inserted. This extracts the vulnerability from the design while maintaining the cantilever's pull-out prevention function.
Solution Approach 2:
The lance structure is designed to prevent wire insertion before the problem can occur. By extending the lance from the front wall with no gap underneath, the design proactively blocks the harmful action of wire snagging while the engaging portion at the rear provides pull-out prevention.
3Ease of manufacture
If a single upper wall structure is used, then manufacturing is simpler, but the lance cannot be securely caught in the housing for effective pull-out prevention
Solution Approach 1:
The upper wall structure is segmented into a front end upper wall and a rear end upper wall, with the lance extending from the front wall. This segmentation provides distinct functional zones: the front wall supports the lance extension for wire prevention, while the rear wall provides the housing engagement structure for secure pull-out prevention.
Solution Approach 2:
The upper wall structure serves multiple functions through its segmentation: the front end upper wall supports the lance extension to prevent wire snagging, while the rear end upper wall provides engagement features for secure housing attachment. This multi-functionality achieves both wire prevention and reliable pull-out resistance.
Data Source
Figure 1(A)~1(B)
Figure 2
Figure 3(A)~3(C)
AI summary
A contact (10) includes side walls (12A, 12B), front end upper walls (13A, 13B, 13F) and rear end upper walls (13A', 13B', 13R), a lance (20), and an extension piece (30). The lance (20) extends rearwardly from the front end upper wall (13F) and has, at its rear end portion (20A), a catch portion (21) that is configured to engage a connector housing. The extension piece (30) has a folded-under portion (31) and an extension portion (32). The folded-under portion (31) is folded downward from a side of the rear end portion (20A) and further folded so as to be located under the rear end portion (20A). The extension portion (32) extends continuously further rearwardly from the folded-under portion (31) so as to be positioned under the rear end upper wall (13R). This configuration of contact (10) provides a contact (10) and connector including such a contact (10) that prevents an electric wire or the like from getting under a lance and, furthermore, allows a greater number of contacts to be made from a given area of material.