Electrical Connector Pin Geometry for Stronger Housing Locking
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Solution Overview
Problem
The existing electrical connectors for coaxial cables face issues with the contact pin shifting or being removed due to insufficient locking force, especially when strong forces are applied or when the mating connectors are not perfectly aligned, leading to reduced signal transmission characteristics.
Innovation Solution
The electrical connector design includes contact pins with protruding portions featuring a front slope and rear slope, which provide increased locking force by ensuring surface contact with the housing's inner surface, preventing shifting and removal even under strong forces, and includes a housing with specific ribs to enhance stability and signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional contact pin with protruding portions is used, then the structure is simple and easy to manufacture, but the locking force is insufficient causing the contact pin to shift or be removed under strong forces
Solution Approach 1:
The invention changes the geometric parameters of the protruding portions by introducing slope surfaces with specific inclination angles (α and β). The front slope portion has an inclination angle α of 10° to 30° relative to the longitudinal direction, and the rear slope portion has an inclination angle β of 5° to 15°. This parameter optimization increases the locking force by improving the engagement between the protruding portions and the housing while maintaining structural simplicity.
Solution Approach 2:
The invention applies curved surface geometry to the protruding portions by forming slope surfaces instead of flat or sharp edges. The front slope portion and rear slope portion create smooth transitional surfaces that increase the contact area with the housing inner peripheral surface. This curvature approach distributes the locking force more effectively and prevents stress concentration, thereby enhancing the overall locking capability without complicating the manufacturing process.
2Reliability
If the contact pin is pressed firmly into the housing, then the initial connection is secure, but the inner peripheral surface of the housing is shaved and the locking force is reduced
Solution Approach 1:
The slope surfaces on the front and rear portions of the protruding portions create curved engagement surfaces that distribute the pressing force over a larger area during insertion. This prevents the concentration of stress at sharp corners that would otherwise shave the inner peripheral surface of the housing. The gradual transition provided by the slope surfaces ensures reliable initial connection while preserving the housing surface integrity and maintaining locking force.
Solution Approach 2:
By optimizing the inclination angles of the slope surfaces (α = 10° to 30° for the front slope, β = 5° to 15° for the rear slope), the invention controls the force distribution during the pressing operation. These parameter settings ensure that the contact pin is firmly secured during insertion while minimizing the risk of shaving the housing inner surface, thus maintaining both connection stability and locking force.
3Strength
If the corner portion of the protruding portion contacts the housing inner surface, then locking is achieved, but the force is concentrated at the contact point causing surface shaving
Solution Approach 1:
The invention replaces the sharp corner portion with smooth slope surfaces that have gradual transitions. The front slope portion and rear slope portion create extended contact zones instead of point contacts. This curvature modification distributes the locking force across larger surface areas, preventing the concentration of stress at specific points that would cause shaving of the housing inner peripheral surface while maintaining effective locking force.
Data Source
AI summary
An electrical connector includes at least one contact pin, an insulating housing for containing the at least one contact pin therein. The at least one contact pin includes a horizontally extending portion, at least one protruding portion extending from the horizontally extending portion in a width direction perpendicular to an insertion and extraction direction of a mating connector. The at least one protruding portion includes a front slope portion and a rear slope portion located closer to the tip side than the front slope portion.