Electrical Connector Direct Contact Spring Clip
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Solution Overview
Problem
Conventional electric connectors experience high total electrical resistance due to 'bulk' and 'permanent' resistances, leading to heating issues, reduced service life, and instability, which affects reliability.
Innovation Solution
The solution involves forming a direct contact between electric conductors and their counterparts by using a common casing with spring clips that securely hold the conductors against metal bump contacts on a printed circuit board, eliminating 'bulk' resistance and reducing 'permanent' resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional contact elements with insulating sheaths are used, then the connector structure is simple and easy to manufacture, but the total electrical resistance is high due to bulk resistance
Solution Approach 1:
The patent removes the insulating sheath from the conductor, extracting the harmful element that caused bulk resistance. The conductor is exposed and directly contacts the contact element, eliminating the high-resistance plastic material from the electrical path while maintaining the simplicity of the overall connector structure
Solution Approach 2:
The patent changes the electrical parameter of the connection path by removing the insulating material, thereby transforming the connection from high-resistance (through plastic) to low-resistance (direct metal-to-metal contact). This parameter change directly addresses the bulk resistance issue while keeping the manufacturing process simple
2Reliability
If direct contact between conductors is formed, then electrical resistance is reduced, but mechanical stability and connection reliability may be compromised
Solution Approach 1:
The patent incorporates a retaining clip that pre-establishes mechanical engagement with the conductor before electrical contact is made. This preliminary mechanical action secures the conductor in position, preventing movement or disconnection while allowing the electrical contact to be formed and maintained stably
Solution Approach 2:
The retaining clip acts as an intermediary element that provides mechanical stability without interfering with the direct electrical contact. It mediates between the need for secure mechanical attachment and the requirement for low-resistance electrical connection, holding the conductor firmly while allowing direct metal-to-metal contact
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 approach significantly reduces total electrical resistance, enhances mechanical stability, and extends the service life of the connector by minimizing thermal effects and ensuring a reliable connection across a wide range of operating temperatures.
Implementation Method 1
a spring clip (14) formed by a bent-back metal strip... capable of pressing, in a loaded state, the portion of electric conductor (26) against the upper face of the printed circuit board (12)
Implementation Method 2
forming a direct contact between at least one electric conductor and the respective counterpart... eliminating the 'bulk' resistance
Data Source
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AI summary
An electric connector is described which provides direct contact between an electric conductor (26) and a respective counterpart (3; 12A; 37). The connection is locked in place by means of one or more spring clips (9; 14), for example associated with a casing (4). In a variant a single common casing (4) is provided for the direct connection between a plurality of electric conductors (26) and respective counterparts, which may be contact elements (3) which are also associated with respective electric conductors (7) or bump contacts (12A) of a PCB (12). In a further variant the counterpart is also an electric conductor (37), in such a way that direct contact is produced between two electric conductors (26, 37) held in mutual engagement by one or more spring clips (14).