Plug-in Connector Contact With Segmented Primary Lance
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Solution Overview
Problem
Existing connectors for vehicle electrical systems face challenges in balancing easy insertion with reliable locking, especially in miniaturized designs subject to high mechanical demands, where conventional primary lances may deform or break under pull-out forces.
Innovation Solution
The contact design separates the primary lance's elastic deflection and locking functions, allowing for a two-dimensional force distribution through a contact surface and locking sub-area, reducing the load on the lance and enabling higher pull-out forces to be absorbed by the housing, while maintaining a compact and material-efficient structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the primary lance is designed to deflect elastically with little force for easy insertion, then the ease of operation is improved, but the reliability of locking under high pull-out forces deteriorates
Solution Approach 1:
The primary lance is segmented into a first area (deflection area) and a second area (locking area), where each area has different mechanical properties. The first area is designed for elastic deflection during insertion, while the second area provides rigid locking under pull-out forces. This segmentation allows the single component to fulfill both contradictory requirements.
Solution Approach 2:
Different regions of the primary lance are assigned different local qualities: the first area has high elasticity for easy deflection during insertion, while the second area has high rigidity for reliable locking. This local differentiation of material or structural properties enables the lance to provide both easy insertion and secure locking.
2Reliability
If the primary lance is made robust to withstand pull-out forces, then the reliability is improved, but the ease of operation deteriorates due to increased insertion force
Solution Approach 1:
The primary lance is divided into functional segments with different mechanical characteristics. The first area is optimized for elastic deflection during insertion operations, while the second area is optimized for withstanding pull-out forces. This segmentation allows the robust locking function without sacrificing ease of insertion.
Solution Approach 2:
The lance structure incorporates local quality variations where the first area has properties suitable for elastic deformation (easier insertion) and the second area has properties suitable for rigid locking (better reliability). This local differentiation resolves the contradiction between robustness and ease of operation.
3Volume of moving object
If miniaturized contacts are used to reduce size, then the volume is reduced, but the mechanical strength deteriorates under high pull-out forces
Solution Approach 1:
Even in miniaturized contacts, the primary lance is segmented into a first area for deflection and a second area for locking. This segmentation allows the small contact to maintain adequate pull-out strength through the rigid second area while remaining compact overall.
Solution Approach 2:
The miniaturized contact incorporates local quality differences in the primary lance, with the second area having higher rigidity for strength while the overall structure remains small. This allows miniaturization without sacrificing the necessary mechanical strength for reliable locking.
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 enhances the contact's ability to absorb higher pull-out forces without deformation or breakage, particularly in miniaturized formats, by distributing forces effectively across a larger contact surface, thereby ensuring secure locking and preventing unintended disengagement.
Implementation Method 1
the primary lance is first elastically deformed inwards so that it can then spring back into a recess in the contact chamber when it reaches its target position
Implementation Method 2
The locking portion of the primary lance and the contact surface are designed and arranged relative to one another such that at least a portion of a force acting in the direction of insertion is transmitted to the contact surface
Data Source
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AI summary
The invention relates to a contact (10) for a plug-in connector, comprising a housing (12) and a primary lance (14) which can be moved inwardly and which can be placed inside the housing (16), said primary lance protruding outwardly, with the locking sub-region (24), past the opening (28). Said contact also comprises a bearing surface (30) for receiving the extraction force between the housing (12) and the primary lance (14).