Contact Spring Frame Geometry for Low-Waste Connector Production
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Solution Overview
Problem
Existing contact elements, electrical connectors, and assemblies are complex and costly to produce, requiring multiple production steps and generating significant material waste.
Innovation Solution
A contact element with a frame and contact springs fixed to the frame, featuring a simplified geometry that allows for single-step production and reduced material waste, with bights to protect and enhance the springs' contact force, enabling reliable connections even with uneven surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If contact elements and electrical connectors are mass produced using conventional methods, then production volume is achieved, but production complexity and costs increase
Solution Approach 1:
The contact element integrates multiple functional components into a single unit: the frame structure, contact springs, and electrical contact features are combined in one piece. This merging eliminates the need for separate manufacturing and assembly steps for these components, thereby reducing production complexity while maintaining mass production capability
Solution Approach 2:
The contact element is designed with universal features that allow it to serve multiple functions: providing electrical contact, maintaining contact force through spring action, and adapting to uneven mating surfaces. This multi-functionality reduces the need for additional specialized components, simplifying the overall production process
2Ease of manufacture
If conventional contact element designs are used, then production methods are established, but material waste increases and versatility is limited
Solution Approach 1:
The contact element incorporates a gap feature that segments the frame structure, allowing for optimized material placement and reduced waste. This segmentation enables precise stamping and bending operations that minimize excess material while maintaining structural integrity and functionality
Solution Approach 2:
The design utilizes variable spring parameters and contact geometry that can be adjusted through stamping and bending processes. These parameter changes allow optimization of material usage while maintaining contact force and electrical performance, reducing material waste without compromising functionality
3Reliability
If contact springs are designed to provide sufficient contact force, then reliable electrical connection is achieved, but risk of overbending and strength loss increases
Solution Approach 1:
The contact spring design incorporates pre-calculated deflection characteristics and geometric features that cushion against overbending. The spring geometry and material selection are optimized beforehand to provide sufficient contact force while preventing excessive deformation that would compromise strength, ensuring reliable electrical connection without strength loss
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
Simplifies production, reduces material waste, and enhances contact force while maintaining versatility, allowing for robust electrical connections without overbending or damage.
Implementation Method 1
The contact spring has a fixed end fixed to the first region of the frame and a free end opposite the fixed end. The contact spring extends from the first region across the gap to the second region. The free end of the contact spring overlaps the second region.
Data Source
AI summary
A contact element includes a frame and a contact spring fixed to the frame. The frame has a first region and a second region opposite the first region. The second region is spaced apart from the first region by a gap. The contact spring has a fixed end fixed to the first region of the frame and a free end opposite the fixed end. The contact spring extends from the first region across the gap to the second region. The free end of the contact spring overlaps the second region.