Connector Contact Protection Tabs for Cantilever Beam Misalignment

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Solution Overview

Problem

Electrical connectors with contact springs often suffer damage due to misalignment during mating, as the mating contact can abut the free ends of the contact springs, impairing the connection and increasing manufacturing complexity and cost.

Innovation Solution

A connector design featuring cantilever beams and protection tabs, where the cantilever beams extend along the insertion direction and protection tabs extend opposite to it, with the tab free ends positioned adjacent to the beam free ends, preventing damage and guiding the connector into proper alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If continuous non-cantilevered contact springs are used to prevent stubbing damage, then reliability is improved, but device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improvecontact spring durabilityVSAvoidcontact spring structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The contact spring is divided into two functional segments: a cantilevered beam portion that provides resilient contact and electrical connection, and a protection tab portion that prevents stubbing damage. This segmentation allows each part to perform its specific function optimally while maintaining manufacturability through standard stamping processes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The protection tab acts as an intermediary element between the mating contact and the cantilevered beam. It intercepts and absorbs the impact of misaligned mating contacts, preventing direct contact with the vulnerable beam free end, thus protecting the contact spring without requiring a complete structural redesign.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If protection tabs are added to cantilevered contact springs to prevent damage, then reliability is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvecontact spring protectionVSAvoidcontact manufacturing

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The protection tab and cantilevered beam are merged into a single monolithic contact structure formed by stamping and bending a single piece of conductive material. This integration eliminates the need for separate assembly operations, maintaining ease of manufacture while providing enhanced protection functionality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The contact is designed with specific geometric parameters including tab width, beam thickness, and free end dimensions that optimize both protection capability and manufacturability. These parameters are controlled through standard stamping and bending processes, ensuring consistency without requiring complex manufacturing steps.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If cantilevered contact springs are used for resilient connection, then ease of operation is improved, but vulnerability to damage increases

Engineering Contradiction:

Improvemating alignment toleranceVSAvoidstubbing damage risk

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The protection tab provides preliminary anti-action by counteracting the harmful effect of misaligned mating contacts before they can reach the cantilevered beam. The tab's position and orientation are designed to intercept potential damaging contacts, neutralizing the harm before it affects the functional beam portion.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The protection tab performs a preliminary protective action during the mating process, guiding the mating contact into proper alignment and preventing damage before the actual electrical connection is established. This preliminary action ensures the cantilevered beam remains intact for reliable operation.

Inventive Principle:

Principle #10Preliminary action

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 effectively protects the cantilever beams from damage during misalignment, allowing for easier and cost-effective manufacturing while ensuring reliable electrical connections by using a monolithic stamping and bending process, and enabling independent height adjustment of the cantilever beams.

Implementation Method 1

Electrical connectors have contacts with contact springs that resiliently abut and electrically connect with a mating contact

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS12170424B2Contact of an electrical connector with protection tabs for cantilever beams

Publication Date: 2024.12.17 TE CONNECTIVITY SOLUTIONS GMBH

AI summary

A contact includes a cantilever beam and a protection tab. The cantilever beam extends from a beam connected end to a beam free end along an insertion direction. The protection tab extends from a tab connected end to a tab free end in a direction opposite to the insertion direction. The tab free end is positioned adjacent to the beam free end.