Plug-In Connector Spring Centering for Conductor Film Contact
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Solution Overview
Problem
Existing plug-in connectors for flexible conductor films with film-insulated conductors often fail to ensure that all blades cut completely through the conductor film, leading to improper electrical contact due to high tolerances and potential cutting into the edge region.
Innovation Solution
A plug-in connector design featuring a second housing part with resiliently arranged spring elements on both sides of the receiving region, which center and position the conductor film precisely, ensuring that blades cut through the center of the conductor film during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the conductor film is inserted through a receiving opening without positioning elements, then the insertion process is simple, but the conductor film cannot be held centrally and blades may cut into the edge region of the conductor
Solution Approach 1:
Positioning elements are pre-integrated into the second housing part before the conductor film is inserted. These positioning elements protrude into the receiving region and are designed to contact the conductor film during insertion, automatically centering it without requiring complex external positioning mechanisms or manual adjustment.
Solution Approach 2:
The positioning elements act as intermediary components between the second housing part and the conductor film. They mediate the interaction by providing mechanical contact points that guide and center the conductor film during the insertion process, ensuring accurate positioning without complicating the overall insertion mechanism.
2Manufacturing precision
If spring elements are added to center and position the conductor film, then positioning accuracy improves, but device complexity increases
Solution Approach 1:
The positioning elements and spring elements are integrated directly into the second housing part as a unified structure. The positioning elements are formed as integral parts of the housing, eliminating the need for separate positioning mechanisms and reducing overall device complexity while maintaining high positioning accuracy.
Solution Approach 2:
The second housing part serves multiple functions: it provides the receiving region for the conductor film, contains the integrated positioning elements for centering, and incorporates spring elements for applying contact pressure. This multi-functionality reduces the need for additional separate components, thereby reducing device complexity while achieving precise positioning.
3Reliability
If blades are moved towards an incorrectly held conductor film to cut into it, then electrical contact may be established, but blades may cut into the insulation material and fail to make proper contact
Solution Approach 1:
The positioning elements are in place before the blades are actuated to cut the conductor film. These positioning elements ensure the conductor film is correctly centered and held in the proper position, preventing the blades from cutting into the insulation material at the edges and ensuring they only cut through the conductor core for reliable electrical contact.
Solution Approach 2:
The spring elements provide a cushioning effect by applying controlled contact pressure to the conductor film before and during the blade cutting action. This ensures the conductor film remains firmly positioned against the positioning elements, preventing excessive blade movement that could cause cutting into the insulation material while still allowing complete penetration of the conductor.
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 spring elements ensure accurate positioning and centering of the conductor film, preventing blades from cutting into the insulation material and ensuring reliable electrical contact by exerting pressure orthogonally, thus addressing the issue of high tolerances and ensuring complete penetration.
Implementation Method 1
a second pair of spring elements arranged resiliently in the receiving region on a second side of the receiving direction
Implementation Method 2
The spring elements ensure accurate positioning and centering of the conductor film, preventing blades from cutting into the insulation material and ensuring reliable electrical contact by exerting pressure orthogonally
Data Source
AI summary
A plug-in connector includes a first housing part having a plug-in contact element and a plurality of blades electrically connected to the plug-in contact element and a second housing part having a receiving region with a receiving direction. The second housing part has a first pair of spring elements arranged resiliently in the receiving region on a first side of the receiving direction and a second pair of spring elements arranged resiliently in the receiving region on a second side of the receiving direction.