Electrical Plug Contact Spring Geometry for Miniaturized Reliability
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Solution Overview
Problem
Miniaturized contact elements for electrical plugs face reduced spring force due to smaller size and wall thickness, impairing the reliability of both electrical and mechanical connections.
Innovation Solution
A contact element design featuring a spring element with a specific ratio of side flanks, where the second side flank is longer than the first, allowing for increased spring force while maintaining miniaturization without compromising the quality of the connection, and incorporating an L-shaped cross-section for enhanced stability and material efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the contact element is miniaturized with smaller size and wall thickness, then the compactness and integration are improved, but the spring force of the contact spring is reduced which impairs the reliability of electrical and mechanical contacting
Solution Approach 1:
The spring element features asymmetric side flanks with different lengths - a first side flank and a second side flank that is longer than the first. This asymmetric geometry allows the spring element to generate sufficient spring force despite miniaturization, as the longer second side flank provides additional leverage and elastic deformation capacity while maintaining a compact overall size.
Solution Approach 2:
The invention changes the geometric parameters of the spring element, specifically the ratio of the second side flank length to the first side flank length (greater than or equal to 0.5). This parameter optimization enables the miniaturized spring element to achieve the required spring force and contact pressure for reliable electrical contacting, resolving the contradiction between size reduction and force maintenance.
2Volume of moving object
If the wall thickness of the contact element is reduced for miniaturization, then the compactness is improved, but the spring force and structural stability are reduced
Solution Approach 1:
The asymmetric side flank design compensates for reduced wall thickness by creating an unequal moment arm distribution. The longer second side flank provides greater mechanical advantage, allowing thin-walled miniaturized structures to generate adequate spring force without requiring increased material thickness.
Solution Approach 2:
The spring element exhibits local quality variations through its asymmetric side flanks, where the longer second side flank is positioned to maximize elastic deformation capacity. This localized geometric optimization allows the miniaturized element to concentrate spring force generation in the most effective region, maintaining force output despite overall size and wall thickness reduction.
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 achieves a reliable and stable electrical connection with increased spring force, balancing miniaturization and connection quality by varying the cut length of the spring element, which allows for effective deflection and energy storage, and provides a high restoring force with controlled permanent deformation.
Implementation Method 1
a spring element (9) deflectable towards and/or away from the base (7). The spring element (9) has a spring base (15) at an end of the spring element (9) connected to the base (7). The spring element (9) extends away from the spring base (15) in a longitudinal direction (17)
Data Source
AI summary
A contact element for an electrical plug includes a base and a spring element deflectable towards and/or away from the base. The spring element is laterally limited by a first side flank and a second side flank. The spring element has a spring base at an end of the spring element connected to the base. The spring element extends away from the spring base in a longitudinal direction. The first side flank is closer to the base than the second side flank and the second side flank faces away from the first side flank. The first side flank has a first length and the second side flank has a second length. A ratio of the second length to the first length is greater than or equal to 0.5.