Electrical Connector Element Reducing Insertion Force
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Solution Overview
Problem
Existing plug-in connection arrangements often require high insertion force due to the need to bend contact elements against external springs, which can be disadvantageous in applications with limited accessible force, compromising the balance between insertion force and contact force.
Innovation Solution
Incorporating a tensioning element that reduces the initial plug-in force by allowing the contact element to be elastically deformed, creating a gap that can be closed to ensure contact, with the effect of the tensioning element canceled automatically during assembly, providing reduced initial insertion force and full contact force upon mating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the contact element is designed to be bent against an external spring to establish contact, then reliable electrical connection is ensured, but the insertion force required increases
Solution Approach 1:
The contact element is pre-deformed during manufacturing to create a prestress state, so that part of the contact force is already present before insertion. This preliminary action reduces the force needed during insertion while maintaining reliable contact in the mated state.
Solution Approach 2:
The patent changes the stress state parameters of the contact element by introducing prestress through pre-deformation. This parameter change allows the contact element to provide sufficient contact force with reduced insertion force, resolving the contradiction between reliability and insertion effort.
2Ease of operation
If the contact element is prestressed to reduce insertion force, then ease of operation improves, but the contact force in the mated state may be insufficient
Solution Approach 1:
The contact element is pre-deformed to establish an initial stress state that facilitates easy insertion. The prestress is calculated and designed so that the contact force in the mated state remains sufficient for reliable electrical connection while reducing insertion force.
Solution Approach 2:
The contact element's stress state dynamically changes during insertion: starting with prestress for easy insertion, then transitioning to a higher contact force state when mated. This dynamic behavior allows the element to satisfy both ease of operation and sufficient contact force requirements.
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 solution reduces the initial plug-in force while maintaining a reliable electrical connection, ensuring contact is established early in the process with minimal surface abrasion and secure fixation, even under pressure or tensile forces.
Implementation Method 1
a tensioning element (40), by means of which the contact element (16) and/or an external spring (20) supporting the contact element (16) when making contact can be elastically deformed
Implementation Method 2
the contact element (16) can be brought into electrically connecting contact (52) with the further plug-in connection element (2)
Data Source
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Figure 7
AI summary
The invention relates to an electrical plug connection element (1) having a contact member (16) which can be deformed in a spring-elastic manner and to which the plug connection element (1) can be electrically connected when it is plug-connected to a further plug connection element (2), characterized in that the plug connection element (1) has a clamping element (40) by means of which the contact member (16) and/or a separate spring (20) which supports the contact member (16) when contact is made can be deformed in a spring-elastic manner in such a way that the force which is required to plug-connect the plug connection element (1) to the further plug connection element (2) is reduced, and in that the action of the clamping element (40) can be removed by the plug connection element (1) being plug-connected to the further plug connection element (2), and as a result the contact member (16) can be brought into contact with the further plug connection element (2) so as to establish an electrical connection by way of the provided contact force.