Contact Member With Locking Projection For Wide Displacement
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Solution Overview
Problem
Existing contact members with a base and elastic components have limited movable ranges, leading to potential damage when subjected to strong contact or loads, as only the elastic component is displaced, restricting the overall range of deformation.
Innovation Solution
A contact member featuring a single metal plate with a first flat-plate portion, leg portions, second flat-plate portions, and a projection portion that extends through the space between the leg portions, allowing for wider displacement and locking by the leg portions, thereby inhibiting damage and deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a contact member uses a base component and an elastic component with limited elastic displacement, then the structure is simple and easy to manufacture, but the movable range is limited and damage occurs under strong contact
Solution Approach 1:
The contact member is divided into a base component (first flat-plate portion) and a projection portion (elastic component), where the projection portion can be independently designed with optimized elastic properties. This segmentation allows the elastic component to be specifically engineered for enhanced displacement capability while maintaining overall structural simplicity.
Solution Approach 2:
The elastic modulus, geometry, and dimensions of the projection portion are optimized to achieve greater elastic displacement range. By changing the parameters of the elastic component (such as thickness, length, and cross-sectional area), the movable range is expanded while maintaining structural integrity and resistance to damage under strong contact conditions.
2Reliability
If the elastic component is designed for larger displacement, then the movable range increases, but the component becomes more complex and harder to manufacture
Solution Approach 1:
The elastic function is extracted and concentrated into a dedicated projection portion that is integrally formed with the base component. This allows the elastic displacement capability to be achieved through a single, well-defined geometric feature rather than a complex assembly of multiple elastic elements, thereby maintaining manufacturing simplicity.
Solution Approach 2:
The projection portion is integrally formed with the first flat-plate portion as a single piece, combining the base structure and elastic component into one monolithic element. This integration eliminates the need for separate elastic components and complex assembly processes, reducing device complexity while achieving the desired movable range.
3Reliability
If the spring part is strongly contacted with the casing, then electrical conduction is achieved, but the spring part is bent to be broken or lose its spring property
Solution Approach 1:
The projection portion is designed with optimized elastic properties that allow it to absorb and distribute contact forces from the casing. The elastic deformation of the projection portion acts as a cushion, reducing peak stresses and preventing the spring part from being bent beyond its elastic limit or losing its spring property, while still maintaining reliable electrical conduction.
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 design enhances the movable range of the contact member, preventing damage by allowing the projection portion to displace widely and locking it to prevent deformation, ensuring reliable electrical connection without damage.
Implementation Method 1
a single metal plate having electrical conductivity and elasticity
Implementation Method 2
the projection portion is provided with protruding portions that expand along the first orientation. When the projection portion is displaced at the second side of the second orientation, the protruding portions are locked by the leg portions
Implementation Method 3
a single metal plate having electrical conductivity and elasticity
Data Source
Figure 1A~1I
Figure 2A~2B
Figure 3A~3B
AI summary
A contact member has a first flat-plate portion, a pair of leg portions, a second flat-plate portion, and a projection portion. The pair of leg portions extends from opposite ends of the first flat-plate portion along a first orientation in a direction intersecting with the first flat-plate portion. The second flat-plate portion is connected to a projecting end of the leg portion. The projection portion extends from an end of the first flat-plate portion on a first direction side of a second orientation, which intersects with the first orientation, to the same direction as the direction where the leg portion extends. The projection portion is bent in a second direction of the second orientation to pass through the space between the pair of leg portions, thereby projecting in the second direction of the second orientation. The projection portion is provided with a protruding portion that expands along the first orientation. When the projection portion is displaced in the second direction of the second orientation, the pro-truding portion is locked by the leg portion.