Dual-Plane Contact Assembly for Stable Tolerance Compensation
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Solution Overview
Problem
Existing contact assemblies for electrically conductive contacts often result in insufficient electrical contacting due to a limited number of contact surfaces, leading to instability and uneven contact, and increasing the number of surfaces can make the plug contact statically undetermined.
Innovation Solution
The introduction of an elastically deflectable second contact plane that can deflect to contact the plug contact, increasing the number of electrically conductive contact surfaces and compensating for tolerances, while the rigid first contact plane provides mechanical stability by bearing the main load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of contact surfaces is increased, then electrical contacting is improved, but the plug contact becomes statically undetermined and cannot contact surfaces uniformly
Solution Approach 1:
The contact assembly is segmented into two distinct contact planes: a first contact plane with rigid contact surfaces that provides mechanical stability and statical determinateness, and a second contact plane with elastically deflectable contact surfaces that increases electrical contacting reliability. This segmentation allows each plane to fulfill different functions without compromising the other.
Solution Approach 2:
Different parts of the contact assembly have different mechanical properties: the first contact plane features rigid contact surfaces for mechanical stability, while the second contact plane features elastically deflectable contact surfaces for tolerance compensation and enhanced electrical contact. This local differentiation of properties resolves the contradiction between stability and contacting reliability.
2Reliability
If the number of contact surfaces is increased, then electrical contacting is improved, but device complexity increases
Solution Approach 1:
The invention merges two contact planes with different characteristics into a single integrated contact assembly that works together to provide both mechanical stability and enhanced electrical contacting. The elastically deflectable contact bodies of the second plane are integrated with the rigid contact bodies of the first plane, creating a unified structure that achieves multiple functions without requiring separate systems.
Solution Approach 2:
The contact assembly serves multiple functions simultaneously: the first contact plane provides mechanical support and statical determinateness, while the second contact plane provides additional electrical contacting paths and tolerance compensation. This multi-functionality is achieved within a single integrated structure, avoiding the need for separate complex systems.
3Adaptability or versatility
If elastically deflectable contact bodies are added to increase contact surfaces, then tolerance compensation is improved, but mechanical stability may be reduced
Solution Approach 1:
The contact assembly is segmented into two distinct contact planes: a first contact plane with rigid contact surfaces that provides mechanical stability and statical determinateness, and a second contact plane with elastically deflectable contact surfaces that increases electrical contacting reliability. This segmentation allows each plane to fulfill different functions without compromising the other.
Solution Approach 2:
Different parts of the contact assembly have different mechanical properties: the first contact plane features rigid contact surfaces for mechanical stability, while the second contact plane features elastically deflectable contact surfaces for tolerance compensation and enhanced electrical contact. This local differentiation of properties resolves the contradiction between stability and contacting reliability.
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
This configuration ensures stable and uniform electrical and mechanical contacting by increasing the number of contact surfaces and improving mechanical stability, allowing the plug contact to securely bear on all surfaces.
Implementation Method 1
a second contact plane which is spaced apart from the first contact plane in the plug-in direction and which projects beyond the first contact plane in the height direction, this second contact plane being spanned by a plurality of contact surfaces on contact bodies that are elastically deflectable at least up to the first contact plane
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a contact assembly (3) for contacting an electrically conductive contact, with a first contact plane (56) that is formed by a plurality of contact surfaces (54), wherein the contact assembly has a second contact plane (66) spaced apart from the first contact plane (56) and projecting beyond the first contact plane (56), this second contact plane (66) being spanned by a plurality of contact surfaces (68) on contact bodies (70) that are elastically deflectable at least up to the first contact plane (56). Through the contact assembly (3) according to the invention, the number of electrically conductive contacted contact surfaces (54, 68) can be increased in a simple manner, wherein the elastically deflectable contact bodies (70) of the second contact plane (66) can compensate for tolerances. From a mechanical point of view, the electrically conductive plug contact (55) bears mainly on the contact surfaces (54) of the first contact plane (56), which makes the system mechanically more stable.