Electrical Connector Contacts With Slanted Leading Surfaces
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Solution Overview
Problem
Existing electrical connectors face issues with smooth mating and potential cracking during assembly due to excessive force, as the U-shaped contacting portions of the receptacle contacts fail to engage properly with the plug terminals.
Innovation Solution
The electrical connector features an insulating housing with slanted linear leading surfaces on the connecting portions of its contacts, allowing for smooth engagement and enhanced elastic force during mating, preventing cracking and ensuring secure contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the U-shaped contacting portion of the receptacle contact is used for engagement, then electrical connection is achieved, but the mating process is not smooth and cracking may occur due to excessive force
Solution Approach 1:
The contact structure is segmented into three functional portions: a U-shaped contacting portion for electrical engagement, a connecting portion with a linear leading surface for guidance, and a holding portion for retention. This segmentation allows each portion to perform its specific function optimally, resolving the contradiction between reliable electrical connection and smooth mating.
Solution Approach 2:
The linear leading surface on the connecting portion performs a preliminary guidance action before the contacting portion engages with the terminal. This preliminary action aligns the components properly, ensuring smooth mating and preventing excessive force that could cause cracking, while still achieving reliable electrical connection.
2Ease of manufacture
If the contact structure is simple with U-shaped contacting portion, then manufacturing is easy, but mating force distribution is poor causing cracking
Solution Approach 1:
The contact is divided into distinct segments (contacting portion, connecting portion, holding portion) that can be manufactured using standard stamping processes. This segmentation maintains manufacturing simplicity while improving strength by distributing mating forces across multiple structural elements rather than concentrating them in a single U-shaped portion.
Solution Approach 2:
The connecting portion extends in a new dimensional direction between the contacting portion and holding portion, creating a more distributed three-dimensional structure. This dimensional extension allows mating forces to be distributed along the length of the connecting portion, increasing overall strength without complicating the manufacturing process.
3Reliability
If the contact providing strong engagement force is used, then electrical connection is secure, but the mating process becomes difficult and may cause cracking
Solution Approach 1:
The linear leading surface performs a preliminary alignment and guidance function before the contacting portion engages with the terminal. This preliminary action reduces mating difficulty by ensuring proper alignment, while the U-shaped contacting portion still provides secure electrical connection once engaged.
Solution Approach 2:
The contact structure exhibits dynamic behavior during mating: the linear leading surface first guides the terminal with minimal resistance, then the U-shaped contacting portion engages to provide secure electrical connection. This dynamic progression resolves the contradiction between easy mating and secure connection.
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 solution provides a smoother mating process and increased durability by reducing the risk of cracking, ensuring reliable electrical connections and improved assembly efficiency.
Implementation Method 1
said connecting portion has a linear leading surface which is formed slanted towards said contacting portion downwardly
Implementation Method 2
enhanced elastic force during mating
Data Source
AI summary
An electrical connector mounted on a PCB (printed circuit board) includes an insulating housing having a receiving room and a plurality of contacts retained in the insulating housing. Said insulating housing has a tongue portion and a peripheral wall surrounds said tongue portion which defines said receiving room. Each contact includes a U-shaped contacting portion received in said receiving room, a vertical holding portion retained in an inner surface of said peripheral wall and a connecting portion connecting with said contacting portion and said holding portion. Said connecting portion has a linear leading surface which is formed slanted towards said contacting portion downwardly in order to provide a smooth mating process with a mating connector.