Connector Passage Width Design for Reliable Contact Pin Insertion
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Solution Overview
Problem
Existing plug connectors face issues where the contact pin insertion opening becomes blocked by an electrical conductor when no contact pin is inserted, preventing the subsequent insertion of a contact pin and compromising electrical contact reliability.
Innovation Solution
The contact pin insertion opening is designed with a reduced passage width adjacent to the conductor connection space, allowing the electrical conductor to be displaced and ensuring the contact pin can be inserted while maintaining reliable electrical contact by concentrating the spring force on a narrow contact surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the contact pin insertion opening has a wide passage to the conductor connection space, then the electrical conductor can be easily inserted and displaced, but the contact pin insertion opening becomes blocked when no contact pin is inserted
Solution Approach 1:
The passage in the contact pin insertion opening has a reduced width specifically in the region adjacent to the conductor connection space, while other parts of the opening maintain their original dimensions. This local modification allows the passage to restrict conductor displacement into the insertion opening while still permitting contact pin insertion, thus resolving the contradiction between ease of conductor insertion and contact pin insertion reliability
2Reliability
If the electrical conductor is pressed firmly by the spring element, then reliable electrical contact is achieved, but the contact pin cannot be inserted due to blocked passage
Solution Approach 1:
The passage width is reduced locally in the region adjacent to the conductor connection space, creating a physical barrier that prevents the electrical conductor from completely blocking the contact pin insertion opening while still allowing the spring element to press the conductor firmly for reliable electrical contact
3Reliability
If the passage width is reduced to prevent conductor blocking, then contact pin insertion is enabled, but the displacement area for the electrical conductor is reduced
Solution Approach 1:
The passage width reduction is applied only in the specific region adjacent to the conductor connection space, while other regions of the contact pin insertion opening maintain sufficient width to provide adequate displacement area for the electrical conductor, thus balancing contact pin insertion capability with conductor displacement volume
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 keeps the contact pin insertion opening free, allows for reliable electrical contact between the contact pin and the electrical conductor, and reduces contact resistance, ensuring effective electrical connectivity.
Implementation Method 1
with a spring clamp connection in an associated conductor connection space with a spring element, which has a clamping section that can be displaced by spring force
Data Source
Figure 1a
Figure 1b~1c
Figure 1d~1e
AI summary
A connector (1) with an insulating housing (2) is described, which has at least one contact pin insertion opening (8) on a first housing side (7) for inserting electrically conductive contact pins (15) and at least one conductor insertion opening (6) on a second housing side (5) for inserting uninsulated ends (14) of electrical conductors (13). Each pair of contact pin insertion opening (8) and conductor insertion opening (6) is associated with a common conductor connection compartment (4). The conductor insertion opening (6) opens into the conductor connection compartment (4), and the contact pin insertion opening (8) has a passage (9) to the conductor connection compartment (4).The connector also has a spring-loaded clamping connection in an associated conductor connection space (4) with a spring element (3) which has a clamping section (12) that can be displaced by spring force transversely to the extension direction of a pair of contact pin insertion opening (8) and conductor insertion opening (6) such that when an insulation-free end (14) of an electrical conductor (13) is inserted into the conductor insertion opening (6), the insulation-free end (14) is pressed towards the contact pin insertion opening (8).The at least one contact pin insertion opening (8) has, over a length in its extension direction from the first housing side (7) to the second housing side (5), at least in the area above the clamping section (12) towards the second housing side (5) and below the clamping section (12) towards the first housing side (7), a width (B1) of the passage (9) which is less than the width (B2) between the opposing side walls of the conductor connection space (4) adjacent to the transition to the contact pin insertion opening (8).