Electrical Connector Contact with Spring-Loaded Blocking Portions

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Solution Overview

Problem

Existing contacts for electrical connectors have unreliable hook engagement due to complex formation processes and structural issues, leading to inconsistent performance.

Innovation Solution

A contact design featuring a first contact pin with ear portions and a second contact pin with resilient beams, where the beams are confined by the ear portions and a coiled spring, allowing for reliable engagement and easy formation, with the resilient beams clamping the first body portion in the latched position.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If hooks are formed on contact pins to enable engagement, then engagement capability is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveengagement reliabilityVSAvoidhook formation complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent removes the hooks from the contact pin structure entirely. Instead of forming hooks on the contact pins, the design uses a spring mechanism with blocking portions that engage with corresponding features on the mating contact, eliminating the complex hook formation process while maintaining engagement functionality.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of using protruding hooks to achieve engagement, the patent uses blocking portions that prevent disengagement. The engagement mechanism is inverted from an active hook-interlock system to a passive blocking system where the spring-loaded blocking portions prevent the contact pins from separating.

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If complex hook structures are used for engagement, then engagement capability is improved, but device complexity increases

Engineering Contradiction:

Improveengagement reliabilityVSAvoidcontact structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts and removes the complex hook structures from the contact design. The engagement functionality is achieved through a simpler spring mechanism with blocking portions that interact with corresponding features on the mating contact, significantly reducing structural complexity.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The spring mechanism serves multiple functions: it provides the blocking portions for engagement, acts as a resilient element to maintain contact force, and enables the latched/unlatched positioning. This multi-functional design eliminates the need for separate hook structures and reduces overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If resilient beams are used for engagement, then engagement reliability is improved, but the beams may distort or break

Engineering Contradiction:

Improveengagement reliabilityVSAvoidresilient beam durability

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent incorporates the spring mechanism to provide beforehand cushioning for the blocking portions. The spring absorbs and distributes the engagement forces, preventing sudden shocks from causing distortion or breakage of the resilient beams, thereby protecting their structural integrity.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent modifies the physical parameters of the engagement mechanism by using a spring-loaded blocking portion system instead of rigid hooks. This changes the force distribution and stress characteristics on the resilient beams, reducing peak stresses that could lead to distortion or breakage while maintaining engagement reliability.

Inventive Principle:

Principle #35Parameter changes

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

The design ensures reliable engagement between the contact pins, simplifies the manufacturing process, and protects the resilient beams from distortion or breakage, enhancing the durability and functionality of the electrical connector.

Implementation Method 1

The spring is compressible between the pair of first blocking portions and the pair of second blocking portions

Methodology Applied

Scientific EffectSpring compression: Spring

Implementation Method 2

a pair of resilient beams slidable between a latched position and an unlatched position. The resilient beams clasp the first body portion in the latched position

Methodology Applied

Scientific EffectResilient beam elasticity: Elasticity

Data Source

PatentUS8157601B2Contact for electrical connector

Publication Date: 2012.04.17 HON HAI PRECISION INDUSTRY CO LTD

AI summary

A contact (1) includes a first contact pin (2), a second contact pin (3) and a spring (4). The first contact pin includes a mating end (26), a body (23) having a first body portion (232) and a second body portion (231), a pair of ear portions (24) and a pair of first blocking portions (22). The first body portion has a thickness greater than that of the second body portion. The second contact pin includes a pair of second blocking portions (32), and a pair of resilient beams (33) slidable between a latched position and an unlatched position. The resilient beams are confined by the ear portions. The resilient beams clasp the first body portion in the latched position. The spring is compressible between the pair of first blocking portions and the pair of second blocking portions.