Connector Contact With Segmented Cylindrical Sections and Protrusion Ribs
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Solution Overview
Problem
Existing electrical connectors face issues with positional deviation of contacts within the insulative body, leading to unreliable electrical connections due to gaps between the contact and the insulative body, caused by the contact's movable nature during assembly.
Innovation Solution
A contact design featuring a first and second cylindrical section with a transition section and protrusion ribs, ensuring precise engagement with the insulative body through an interference fit, preventing offset and enhancing positional stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a gap is disposed between the contact and the insulative body after assembly, then the contact can be easily installed, but the contact becomes movable and may be easily offset from its correct installation position
Solution Approach 1:
The contact is divided into multiple sections (first cylindrical section, second cylindrical section, and transition section) with different diameters, allowing each section to serve different functions: the first cylindrical section with larger diameter provides ease of installation while the second cylindrical section with smaller diameter and protrusion ribs ensures precise positioning
Solution Approach 2:
Different sections of the contact have different geometric properties - the first cylindrical section has a larger diameter for easy insertion, while the second cylindrical section has a smaller diameter and protrusion ribs for precise positioning, creating local quality variations that solve both installation ease and positioning accuracy
2Ease of manufacture
If the contact is formed by stamping and bending a metal plate, then the manufacturing process is simple, but a gap is disposed between the contact and the insulative body leading to unreliable electrical connection
Solution Approach 1:
The protrusion ribs are pre-formed on the contact during the stamping and bending process, creating an interference fit structure in advance that prevents gaps from forming during assembly, thereby ensuring reliable electrical connection while maintaining manufacturing simplicity
3Ease of operation
If the contact is movable within the insulative body, then the assembly process is easier, but large positional deviation occurs after assembly
Solution Approach 1:
The contact is segmented into different cylindrical sections with the second cylindrical section featuring protrusion ribs that engage with the insulative body, allowing easy insertion while preventing positional deviation through the interference fit of the ribs
Solution Approach 2:
The contact features asymmetric geometry with the second cylindrical section having a smaller diameter and protrusion ribs compared to the first cylindrical section, creating a non-uniform structure that provides both ease of insertion and precise positioning through the rib-insulative body engagement
Data Source
AI summary
A contact comprises a first cylindrical section, a second cylindrical section, and a transition section connected between the first cylindrical section and the second cylindrical section. The first cylindrical section has a first peripheral wall with a first diameter and a first protrusion rib disposed on the first peripheral wall. The second cylindrical section has a second peripheral wall with a second diameter less than the first diameter and a second protrusion rib disposed on the second peripheral wall.