Electrical Connector Contact Arm Offset Geometry
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Solution Overview
Problem
Existing electrical connectors with contact arms face issues such as high insertion force due to resistance from contact arm growth and limited space, leading to increased manufacturing costs and complexity, particularly in two-piece designs fabricated using screw machine processes.
Innovation Solution
The design includes a cylindrical body with contact arms extending from a terminating segment to an end segment, featuring intermediate points offset along the circumference, which reduces arm growth and insertion force, and can be fabricated from a sheet of material, simplifying assembly and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If contact arms are made longer to reduce insertion force, then insertion force decreases, but contact arm growth during engagement increases
Solution Approach 1:
The contact arm is designed with a dynamic geometry where the intermediate point is offset from the radial line connecting the ends. This creates a non-uniform deflection pattern during engagement, allowing the contact arm to grow less in length while still providing sufficient compliance to reduce insertion force. The offset intermediate point enables the contact arm to flex in a controlled manner that balances insertion force reduction with minimal growth.
2Area of stationary object
If contact arms are made shorter to fit within limited space, then space utilization improves, but moment of inertia decreases requiring higher insertion force
Solution Approach 1:
The contact arm features non-uniform cross-sectional properties along its length, with the intermediate point having different characteristics than the ends. This local variation in geometry optimizes the moment of inertia distribution, providing sufficient resistance to bending where needed while maintaining compact overall dimensions. The offset intermediate point creates local stiffness variations that reduce insertion force without requiring the contact arm to extend beyond available space.
3Manufacturing precision
If two-piece contact design with screw machine process is used, then manufacturing precision improves, but manufacturing cost and complexity increase
Solution Approach 1:
The contact arm is designed as an integrated component where the intermediate point and ends form a continuous structure without separate inserts or assemblies. This merging of features into a single monolithic component eliminates the complexity of two-piece construction and screw machine processes, while maintaining manufacturing precision through modern forming techniques. The offset intermediate point geometry can be directly formed in a single piece, reducing assembly steps and manufacturing cost.
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 reduces insertion force, minimizes material waste, and simplifies manufacturing, resulting in a more efficient and cost-effective electrical connector with longer contact arms that do not excessively grow during engagement.
Implementation Method 1
the mating contact engages and deflects the mating interfaces of the contact arms radially outward. Resistance to the deflection by the mating contact facilitates establishing a reliable engagement and electrical connection
Data Source
AI summary
An electrical contact includes an at least partially cylindrical body having a terminating segment and an end segment. A contact arm extends from the terminating segment to the end segment. The contact arm includes a contact tip that is configured to engage a mating contact to electrically connect the body to the mating contact. The contact arm defines a portion of a circumference of the body. The contact arm extends from the terminating segment and the end segment at corresponding ends of the contact arm. The contact arm includes an intermediate point that is located between the ends and that is offset from at least one of the ends along the circumference of the body.