Integrated Contact Body With Plastically Deformed Spring Leg
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Solution Overview
Problem
Existing contact elements are complex and costly to produce, requiring multiple components and assembly steps, which complicates their manufacturing process.
Innovation Solution
A contact element design where the first spring leg is positively connected to the contact body using a fastening device that is plastically deformed to create a form-fitting, resilient connection, allowing for simplified assembly and potentially eliminating the need for an enclosed housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional contact elements are designed with separate housing and spring element components, then the structural integrity and functionality are ensured, but the number of components increases and manufacturing complexity rises
Solution Approach 1:
The patent combines the housing and spring element into a single integrated contact body manufactured as one piece. The spring element is formed directly from the contact body material, eliminating the need for separate housing and spring components. This merging reduces assembly steps and component count while maintaining the structural functions of both the housing and spring element.
Solution Approach 2:
The contact body is segmented into functional regions: a mounting section for attachment, a spring section for mechanical compliance, and contact sections for electrical connection. This segmentation allows each region to perform its specific function while being manufactured as a single integrated component, resolving the contradiction between structural integrity and component complexity.
2Reliability
If multiple assembly steps are used to attach the spring element to the contact body, then the connection reliability is improved, but the manufacturing time and cost increase
Solution Approach 1:
The spring element and contact body are manufactured as a single integrated component using additive manufacturing or similar processes. This eliminates all assembly steps required to attach separate spring elements to housings, significantly improving manufacturing efficiency while maintaining connection reliability through the continuous material structure.
Solution Approach 2:
The spring element geometry is pre-formed during the manufacturing of the contact body itself, rather than being assembled later. The spring sections are created directly in their final functional configuration during the primary manufacturing process, eliminating subsequent assembly operations and reducing manufacturing time.
3Reliability
If an enclosed housing is used to secure the spring element, then the protection and stability are improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The housing structure and spring element are merged into a single contact body. The mounting section provides the protective enclosure function while the spring section provides the mechanical compliance, all within one continuously manufactured component. This eliminates the need for separate enclosed housings while maintaining protection and stability.
Solution Approach 2:
The manufacturing method is changed from traditional subtractive or assembly-based approaches to additive manufacturing or monolithic forming. This parameter change in the manufacturing process enables the creation of complex integrated geometries that provide both protective housing and spring functionality without requiring multiple separate components or expensive multi-step manufacturing processes.
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 the number of components and assembly complexity, enabling cost-effective production and ensuring a secure, reliable electrical connection while providing protection against the electrical line being pushed out.
Implementation Method 1
the fastening device is plastically deformed by bending or otherwise plastically deforming it, so that a firm, load-bearing, positive-locking connection is established between the spring element and the contact body
Implementation Method 2
a spring element arranged on the contact body which has a first spring leg for supporting the contact body and a second spring leg for interacting with an electrical conductor inserted into the plug-in space
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a contact element (1) comprising an electrical contact portion (11) for insertion connection to an associated mating contact element (3), a contact body (10), which is connected to the contact portion (11) and forms an insertion space (14), into which an electrical line (2) can be inserted in an insertion direction (E) for electrical connection to the contact element (1), and a spring element (12), which is arranged on the contact body (10) and has a first spring leg (120) for supporting on the contact body (10) and a second spring leg (121) for interaction with an electrical line (2) inserted into the insertion space (14). The first spring leg (120) can be interlockingly connected to the contact body (10) by the placement of an opening (122) of said first spring leg (120) onto a fastening device (104) of the contact body (10).