Connector Assembly Deformable Contact Cleaning
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Solution Overview
Problem
Existing connector assemblies often fail to achieve good electrical connections between wiring sheets due to foreign substances and oxide films, requiring an additional cleaning step that increases manufacturing time and cost.
Innovation Solution
A forming method for a connector assembly that includes a main connector, a first wiring sheet, and a second wiring sheet, where the sheets are arranged with deformable portions that are pressed together by an auxiliary connector, rubbing off contaminants and establishing contact without the need for a separate cleaning step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cleaning step is added to remove foreign substances and oxide films from terminals, then electrical connection quality is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent applies preliminary action by forming the deformable portion with the contact in advance, positioned over the receiving portion, so that the cleaning and contact establishment happen automatically during the pressing assembly process rather than requiring a separate cleaning step beforehand
Solution Approach 2:
The deformable portion with contact serves a dual function: it both cleans the contact surfaces through friction during pressing and simultaneously establishes the electrical connection, allowing the same component to perform both cleaning and connection functions without requiring separate dedicated cleaning mechanisms
2Reliability
If a cleaning step is added to remove foreign substances and oxide films from terminals, then electrical connection quality is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges the cleaning function and connection establishment function into a single integrated process. The deformable portion with contact performs both cleaning (by rubbing against the second contact) and connection establishment simultaneously during pressing, eliminating the need for separate cleaning equipment and processes
Solution Approach 2:
The contact structure serves itself by using its own deformation and friction during the pressing process to clean the contact surfaces, rather than requiring external cleaning systems. This self-cleaning capability reduces manufacturing complexity and cost
3Reliability
If deformable portions are pressed together to establish contact, then electrical connection is achieved, but the resilient portion must be designed to withstand deformation forces
Solution Approach 1:
The patent applies dynamics by designing the deformable portion to be elastically deformable rather than rigid. The resilient portion dynamically adjusts during pressing, deforming to accommodate the pressing force and then recovering to maintain contact pressure, which distributes mechanical stress and prevents failure
Solution Approach 2:
The resilient portion provides beforehand cushioning by being pre-designed with elastic properties that absorb and distribute the deformation forces during pressing. This elastic cushioning effect protects the contact structure from excessive mechanical stress that could cause damage
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 method ensures good electrical connections between the wiring sheets without additional cleaning, reducing manufacturing time and cost by using resilient deformable portions to clean and maintain contact between the sheets during assembly.
Implementation Method 1
at least one of the receiving portion and the received portion is provided with a resilient portion which is resiliently deformable
Implementation Method 2
the first deformable portion and the second deformable portion are deformed and pushed into the receiving portion... the first contact and the second contact are located within the receiving portion to be in contact with each other
Data Source
AI summary
A connector assembly comprises a main connector, a first wiring sheet and a second wiring sheet. The main connector has a receiving portion. The first wiring sheet has a first positioned portion, a first deformable portion extending from the first positioned portion and a first contact provided on the first deformable portion. The second wiring sheet has a second positioned portion, a second deformable portion extending from the second positioned portion and a second contact provided on the second deformable portion. When the connector assembly is assembled, the first positioned portion and the second positioned portion are positioned by a positioning jig. Then, the first deformable portion and the second deformable portion are pressed downward to be pushed into the receiving portion so that the first contact and the second contact are located within the receiving portion to be in contact with each other.