Electrical Contact Overlapping Structure Assembly
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Solution Overview
Problem
Conventional electrical contacts for IC-PCB connections are difficult to manufacture, assemble, and are costly due to complex assembly processes and high machining requirements, leading to low productivity and susceptibility to abrasion.
Innovation Solution
An electrical contact with an overlapping structure comprising a first contact pin, a second contact pin, and an elastic member, featuring guiding and stopping portions, and slots for secure interlocking and easy assembly, reducing manufacturing complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional cylindrical contact pins with openings are used, then the electrical contact can be assembled, but the assembly process becomes complicated and productivity decreases
Solution Approach 1:
The patent merges the contact pin and the guiding structure into a single integrated component. The contact pin includes integrated guiding portions with guiding grooves that directly guide the movement of the other contact pin, eliminating the need for separate guiding components and openings in the pipe body. This integration simplifies the assembly process to merely inserting the contact pins into the pipe body, significantly improving productivity.
2Reliability
If conventional cylindrical contact pins are used, then the electrical contact can function, but the manufacturing cost increases due to large amount of machining work
Solution Approach 1:
The contact pin is segmented into functional portions: a contacting portion for electrical contact, guiding portions with guiding grooves for movement guidance, and a stopping portion for positioning. This segmentation allows each portion to be optimized for its specific function while simplifying the overall manufacturing process, as the guiding grooves can be formed directly on the contact pin body without complex separate components.
Solution Approach 2:
The contact pin serves multiple functions simultaneously: it provides electrical contact through the contacting portion, guides the movement of the other contact pin through the integrated guiding grooves, and positions itself and the other contact pin through the stopping portion. This multi-functionality eliminates the need for separate guiding components, reducing machining work and manufacturing cost while maintaining functional reliability.
3Ease of operation
If openings are provided in the pipe body for contact pin insertion, then the contact pins can be inserted, but the openings are easily abraded by high-frequency friction
Solution Approach 1:
The patent extracts the guiding function from the pipe body openings and relocates it to the contact pin itself through integrated guiding grooves. This eliminates the need for openings in the pipe body, thereby removing the source of high-frequency friction and abrasion. The contact pins are simply inserted into the pipe body without requiring repeated sliding through openings, significantly improving durability.
4Reliability
If upper and lower contact pins are arranged uprightly in a line with spring, then the electrical contact can be assembled, but the assembling process becomes complicated
Solution Approach 1:
The patent merges the guiding function into the contact pins themselves through integrated guiding grooves and guiding portions. This eliminates the need for separate guiding components and complex assembly steps, reducing device complexity while maintaining the upright linear arrangement and electrical connection reliability. The assembly process is simplified to merely inserting the contact pins into the pipe body, where they self-align and self-guide.
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 overlapping structure facilitates easier assembly, enhances stability, and reduces manufacturing costs while maintaining a secure electrical connection, improving productivity and durability.
Implementation Method 1
an elastic member surrounding the first contact pin and the second contact pin
Data Source
AI summary
An electrical contact includes a first contact pin, a second contact pin and an elastic member surrounding the first contact pin and the second contact pin. Both of the first contact pin and the second contact pin include contacting portions. The first contact pin has a guiding portion including two lead-in arms and a stop portion between the two leading arms. The second contact has a main body and a protrusion on a top end of the main body. The leading arms define a guiding groove therebetween for the main body of the second contact pin moving up and down. The protrusion abuts against the stop portion of the first contact pin to prevent the second contact from sliding out of the guiding groove.