Contact Socket Segmented Ridges for Stable Resistance
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Solution Overview
Problem
Existing contact sockets for electrical connectors face challenges in maintaining low and stable electrical contact resistance over a high number of mating cycles due to oxidation and dirt accumulation, which increases contact resistance and requires complex cleaning or lubrication processes.
Innovation Solution
A contact socket with a cylindrical receiving section made from electrically conductive material, featuring contacting webs on the inner circumference that can resiliently spread open to accommodate a contact pin, allowing for low insertion and withdrawal forces and effective removal of contaminants, and optionally treated for improved wear resistance and electrical conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wires or strips are arranged within the cylindrical interior to improve mechanical and electrical connection, then contact resistance decreases, but oxidation and dirt layers form on surfaces over time increasing contact resistance
Solution Approach 1:
The contact socket is segmented into contact ridges (protrusions) and valleys (grooves) on the inner circumference. This segmentation creates multiple discrete contact points while the valleys between ridges facilitate contaminant removal, resolving the contradiction between maintaining low contact resistance and preventing oxidation/dirt accumulation.
Solution Approach 2:
The patent converts the harmful effect of friction during insertion into a beneficial cleaning action. The contact ridges are designed to scrape against the contact pin surface during insertion, removing oxidation and dirt layers. This transforms the potentially harmful friction into a self-cleaning mechanism that maintains low contact resistance over time.
2Reliability
If contact ridges are formed on the inner circumference to improve contact, then mechanical and electrical coupling is enhanced, but insertion and withdrawal forces increase
Solution Approach 1:
The contact ridges are positioned only at specific locations on the inner circumference rather than forming a continuous surface. This local concentration of contact features provides sufficient mechanical and electrical coupling while minimizing the total contact area, thereby reducing insertion and withdrawal forces compared to a full-surface contact design.
Solution Approach 2:
The contact ridges feature curved or rounded surfaces rather than sharp edges. This curvature distributes the contact pressure more evenly during insertion and withdrawal, reducing peak forces while maintaining effective mechanical and electrical coupling. The rounded geometry also facilitates smoother engagement and disengagement.
3Reliability
If the receiving section is made resilient to expand when contact pin is inserted, then contact pressure is maintained, but manufacturing complexity increases
Solution Approach 1:
The patent achieves resilience and expandability by changing the material parameters of the receiving section. The contact socket is made from elastomeric or thermoplastic materials that inherently possess elastic properties, allowing the structure to expand upon insertion and maintain contact pressure without requiring complex mechanical spring mechanisms or additional components.
Solution Approach 2:
The patent merges the structural body of the receiving section with the contact ridges themselves. The contact ridges are not separate components but are integrally formed as part of the receiving section wall. This integration simplifies manufacturing while maintaining the resilient expansion capability, as the entire structure can deform elastically to accommodate the contact pin.
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 ensures low and stable contact resistance, reduced wear, and easy maintenance, with minimal insertion forces and no need for complex cleaning, even in harsh environments, while preventing oxide layer formation and maintaining performance over a high number of cycles.
Implementation Method 1
The receiving section is manufactured using a stamping/bending process and is held in shape movably by means of a material toothing such that the interior, formed with the contact ridges on the inner circumference, can be expanded resiliently, particularly when the contact pin is inserted or plugged into the open end of the contact socket
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
The invention relates to a contact socket (100) for an electrical connector, comprising an elongated receiving section (101) made of an electrically conductive material, essentially cylindrical in shape and defining a longitudinal axis, which extends from a first end section (102) to an open end (103). The receiving section (101) provides an interior space (104) towards the open end (103) formed with contact ridges (110) on its inner circumference, wherein the receiving section (101) is manufactured by a stamping/bending process and is movably held in shape by means of a material toothing (109) such that the interior space (104) formed with the contact ridges (110) on its inner circumference can be resiliently expanded, particularly when a contact pin is inserted or plugged into the open end of the contact socket.