Connector Test Slot for Reliable Electrical Contact Testing
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Solution Overview
Problem
Existing plug connectors require precise alignment and high forces for functional testing, which is costly and damages the contact partners, and existing solutions are not cost-effective or durable.
Innovation Solution
Incorporating a test slot in the contact chamber allows for partial overlap between the contact test pin and contact partner, enabling a quick, reliable, and low-force functional test without the need for precise alignment, using a contact test pin that can be inserted for electrical testing within the chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If precise alignment is required for the contact test pin and contact partner, then the electrical function test can be performed, but the manufacturing cost increases and the testing process becomes more complex
Solution Approach 1:
The test slot acts as an intermediary element between the contact test pin and the contact partner. It provides a guided path that automatically aligns the test pin with the contact partner during insertion, eliminating the need for precise pre-alignment while ensuring reliable electrical contact for testing
Solution Approach 2:
The test slot changes the geometric parameters of the testing interface by providing a defined insertion path with appropriate clearance. This allows the contact test pin to self-align during insertion, transforming the alignment requirement from a critical precision parameter to a tolerance-friendly design
2Reliability
If high force is applied during functional testing, then the electrical connection can be tested, but the contact partner may be damaged
Solution Approach 1:
The test slot serves as a protective intermediary that guides the contact test pin along a controlled path. This ensures that the testing force is distributed evenly and applied only to the intended contact area, preventing damage to the contact partner while maintaining reliable electrical connection testing
Solution Approach 2:
The test slot provides a cushioning effect by allowing controlled play and movement of the contact test pin during insertion. This pre-absorbs excessive forces before they reach the contact partner, protecting it from damage while still enabling effective electrical testing
3Measurement precision
If tight tolerances are specified for the adapter, then the functional test accuracy improves, but the manufacturing cost increases
Solution Approach 1:
The test slot acts as a tolerance-compensating intermediary between the adapter and the contact partner. It provides a guided insertion path that ensures accurate positioning of the contact test pin even with larger adapter tolerances, maintaining test accuracy while reducing manufacturing costs
Solution Approach 2:
The test slot changes the tolerance parameters by providing a defined geometric constraint for the contact test pin insertion. This allows the adapter to be manufactured with larger tolerances while the test slot itself ensures the necessary positioning accuracy for reliable testing
Data Source
Figure 1~3
AI summary
The invention relates to a connector (1) comprising a housing (2) made of plastic, wherein the housing (2) has at least one contact chamber (3) in which a contact partner, in particular a socket contact (4), is arranged, which is inserted in the contact chamber (3) and locked at least once, wherein according to the invention it is provided that the contact chamber (3) in the housing (2) has a test slot (6) which receives a contact test pin (5) which can be inserted into the at least one contact chamber (3) for the purpose of functional testing of the connector (1).