Plug Connector Contact Pin Layout for High Retention Force
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Solution Overview
Problem
Existing contact pins for plug connectors face challenges in achieving high retention forces without requiring excessive assembly forces and are often produced inefficiently.
Innovation Solution
A contact pin design with retaining elements arranged at angles less than 90° in the circumferential direction, ensuring each element touches undamaged base material, providing equal retention force contributions and controlled assembly forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If retaining elements are arranged successively along the longitudinal axis, then retention force is increased, but assembly forces become excessively high
Solution Approach 1:
The patent transitions from a single-dimensional longitudinal arrangement of retaining elements to a two-dimensional circumferential distribution. By arranging retaining elements at different circumferential positions (e.g., 0°, 90°, 180°, 270°) around the pin's circumference, the retention force is distributed across multiple spatial dimensions, reducing the peak assembly force required while maintaining high total retention capability.
Solution Approach 2:
The retaining function is segmented into multiple discrete retaining elements distributed circumferentially around the pin. Instead of one or two longitudinal retaining elements, the patent employs multiple elements (typically four) spaced around the circumference, with each element contributing to the total retention force. This segmentation allows the assembly force to be distributed across multiple contact points, reducing the peak force required.
2Strength
If retaining elements are arranged successively along the longitudinal axis, then retention force is increased, but production efficiency decreases
Solution Approach 1:
The patent combines the formation of multiple retaining elements into a single molding operation. All circumferentially distributed retaining elements are created simultaneously during the injection molding process, eliminating the need for separate post-processing steps for each retaining element. This merging of operations maintains high retention force while preserving production efficiency.
Solution Approach 2:
The molding process itself generates the retaining elements as an integral part of the pin structure. The injection molding process automatically forms the retaining elements with the correct circumferential distribution and geometric features, making the production process self-sufficient and eliminating additional manufacturing steps that would reduce productivity.
3Strength
If retaining elements are offset by 90° in the circumferential direction, then both elements touch undamaged base material, but assembly forces become excessively high
Solution Approach 1:
The patent optimizes the local angular positioning of retaining elements relative to the wedge shape geometry. Rather than uniform 90° spacing, the retaining elements are positioned at specific angles (e.g., 45°, 135°, 225°, 315°) that align with the wedge expansion pattern. This local optimization ensures that each retaining element engages undamaged base material while distributing the assembly force efficiently, preventing excessive peak forces.
Data Source
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AI summary
An inventive contact pin for a plug connector comprises a base body with a longitudinal axis x and a surface O. A first end of the contact pin is adapted to be plugged into an opening of a pin strip of the plug connector, the contact pin having at least four retaining elements which are moulded on the base body. Two retaining elements are each arranged successively spaced apart along the longitudinal axis x. Moreover, two further retaining elements are each arranged oppositely at the same point of the longitudinal axis x in the circumferential direction. In this case, the retaining elements arranged successively are arranged offset from one another in the circumferential direction at an angle W1. According to the invention, it is envisaged that the angle W1 is smaller than 90°.