One-Piece Contact Element With Recess Decoupling Lamellae Resilience

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Solution Overview

Problem

Existing contact elements fail to efficiently combine insulation displacement connections and lamellae contacts in a single component while maintaining the mobility and resilience of the lamellae, leading to potential deformations and interference between the two connection methods.

Innovation Solution

A one-piece contact element with an insulation displacement connection at one end and lamellae contacts at the other, featuring a recess to decouple the segments and maintain resilience, supported by a crimped or angled reinforcement to prevent deformations, allowing for secure and stable electrical connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If insulation displacement connection and lamellae contacts are integrated in a one-piece component, then device complexity is reduced and productivity is improved, but the mobility and resilience of the lamellae may be compromised due to interference between the two connection methods

Engineering Contradiction:

Improvestructure integrationVSAvoidlamellae resilience

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The contact element is divided into distinct functional segments: an insulation displacement connection segment and a lamellae contact segment. These segments are separated by a recess that creates independent zones for each connection type, allowing the lamellae to maintain their resilience while the overall structure remains integrated in a one-piece component.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A recess is introduced as an intermediary structural feature between the insulation displacement connection and the lamellae contacts. This recess acts as a decoupling element that prevents stress and deformation from one segment affecting the other, thereby preserving the mobility and elastic properties of the lamellae while maintaining structural integration.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If the lamellae are made resilient to accommodate mating contacts, then ease of operation is improved, but the structural stability may be reduced due to potential deformations

Engineering Contradiction:

Improvecontact accommodationVSAvoidstructural stability

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different parts of the contact element have different mechanical properties optimized for their specific functions. The lamellae are designed with resilient properties for accommodating mating contacts, while the insulation displacement connection segment maintains structural rigidity. The recess locally separates these opposing requirements, allowing each zone to exhibit its intended quality without compromising the other.

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If a recess is introduced to decouple the segments, then manufacturing precision is maintained, but device complexity increases due to additional structural features

Engineering Contradiction:

Improvesegment decouplingVSAvoidrecess structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The recess feature is integrated directly into the one-piece contact element during manufacturing, merging the decoupling function with the overall structure. This approach maintains manufacturing precision by ensuring proper segment separation while avoiding the complexity of assembling separate components, as the recess is formed as an integral part of the stamping or extrusion process.

Inventive Principle:

Principle #5Merging (Combining)

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

Facilitates quick and automatic assembly of electrical connections with improved stability and reduced deformation, enabling efficient electrical contact between components using a single component with integrated insulation displacement and lamellae contacts.

Implementation Method 1

For the lamella(e) to be resilient perpendicularly to the longitudinal extension of the body, and so that the integration of the insulation displacement connection does not interfere with the elasticity of the lamella(e), a recess may be provided in the material of the body between the first and second end segment

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

The 'sharp' contact legs of the insulation displacement connection may sever the insulation of the cable, and a gastight electrical connection to the electrical conductor may be created

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 3

supported by a crimped or angled reinforcement to prevent deformations

Methodology Applied

Scientific EffectStructural Reinforcement:

Data Source

PatentUS9431721B2Contact element

Publication Date: 2016.08.30 LISA DRAXLMAIER GMBH

AI summary

A contact element for creating an electrical contact between a first and a second electrical or electronic component, including a one-piece, elongated, and flat body. The body may include a first end segment, a second end segment opposite the first end segment, an insulation displacement connection site in the first end segment, and a lamellae contact with two lamellae being located at the second end segment. At least one lamella may be resilient.