Converging Electrical Contact Assembly for Wear Reduction

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Solution Overview

Problem

Repeated use of electrical connectors in four-wire sensing circuits leads to physical damage due to sliding and rubbing movements, which reduces their lifespan in applications like circuit manufacturing and testing.

Innovation Solution

A contact assembly with a nonconductive base and dual electrical contacts configured to converge and diverge as the base moves, minimizing sliding or rubbing against connector pins, thus reducing wear and extending the connector's life.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of moving object

If electrical connectors are used for repeated connection and disconnection in four-wire sensing circuits, then the connectors can complete multiple measurement cycles, but the electrical contacts suffer from sliding and rubbing movements that cause physical damage and reduce lifespan

Engineering Contradiction:

Improvelifespan of electrical connectorVSAvoidphysical damage from sliding and rubbing

Core Design Contradiction:

Duration of action of moving objectVSObject-affected harmful factors

Solution Approach 1:

Instead of having the electrical contacts slide along the connector pin during insertion and removal, the patent inverts the engagement mechanism: the contacts are positioned to engage the pin at a fixed point, and the sliding motion is eliminated by designing the contact path to be perpendicular to the insertion direction, thus converting the harmful sliding friction into minimal point contact friction

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent introduces an intermediary engagement mechanism where the electrical contacts engage the connector pin through a defined geometric interface that separates the insertion motion from the contact interface, allowing the connector to be inserted and removed without the contacts sliding against the pin surface

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If traditional electrical contacts are designed to engage connector pins through sliding movement, then connection and disconnection can be achieved, but wear on the electrical contacts increases with each use

Engineering Contradiction:

Improveconnection and disconnection capabilityVSAvoidwear on electrical contacts

Core Design Contradiction:

Ease of operationVSLoss of substance

Solution Approach 1:

The patent inverts the traditional sliding contact mechanism by positioning the electrical contacts to engage the connector pin in a direction perpendicular to the insertion motion, eliminating the sliding component and reducing material loss through friction

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent employs curved or rounded contact surfaces on the electrical contacts and connector pin interface, which distribute the contact pressure and reduce stress concentration, thereby minimizing wear during the engagement and disengagement cycles

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentUS11019730B2Contact assembly

Publication Date: 2021.05.25 HONEYWELL FEDERAL MANUFACTURING & TECHNOLOGIES LLC

AI summary

An electrical contact assembly includes an electrically nonconductive base, a first electrical contact supported by the base and a second electrical contact supported by the base such that the first contact and the second contact are separated by a space. The first electrical contact is configured to engage a first external conductive circuit element and the a second electrical contact is configured to engage a second external conductive circuit element. The first contact and the second contact are configured such that a portion of the first contact and a portion of the second contact converge as the base moves in a first direction relative to the first and second external conductive circuit elements and diverge as the base moves in a second direction relative to the first and second external conductive circuit elements.