Electric Connecting Element With Overspring For Vibration Resistance
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Solution Overview
Problem
Existing connection elements for making electrical contact with plug-in contacts struggle to maintain reliable contact, especially under vibrations, due to inadequate mechanical and electrical conductivity.
Innovation Solution
A connection element with a base part and an overspring that applies a spring force to the contact spring arm, featuring two spaced contact areas and a spacer device for improved contact reliability and reduced insertion force, utilizing different materials for optimal conductivity and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single contact spring arm is used to ensure electrical contact, then the structure is simple, but the contact reliability under vibrations is insufficient
Solution Approach 1:
The contact spring arm is divided into multiple arm segments (front and rear contact areas) that are spaced apart. This segmentation allows each segment to independently engage with the plug contact, providing multiple contact points that enhance reliability under vibrations while maintaining a relatively simple overall structure.
Solution Approach 2:
The overspring surrounds the base part and contact spring arm, creating a nested structure where the overspring applies additional spring force to the contact spring arm. This nested configuration enhances contact reliability through layered spring forces without significantly increasing external dimensions or complexity.
2Ease of operation
If the contact spring arm is made highly flexible to reduce insertion force, then insertion is easier, but the mechanical contact stability decreases
Solution Approach 1:
The contact spring arm is segmented into multiple rigid sections connected by flexible joints. This allows the arm to flex during insertion (absorbing insertion force) while maintaining stable contact areas that provide reliable mechanical engagement once inserted.
Solution Approach 2:
The contact spring arm combines materials with different properties - rigid sections for structural stability and flexible sections for ease of insertion. This composite approach allows the same component to exhibit both flexibility during insertion and stability during operation.
3Reliability
If the contact area is increased to reduce contact resistance, then electrical conductivity improves, but the insertion force required increases
Solution Approach 1:
Instead of one large contact area, the invention uses multiple smaller contact areas (front and rear contact regions) spaced apart along the contact spring arm. This segmentation distributes the electrical contact function across multiple points, reducing total contact resistance while requiring less insertion force than a single large contact area would demand.
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
Ensures permanently reliable mechanical and electrical contact with reduced sensitivity to vibrations, accommodating various plug contact thicknesses and facilitating easy insertion through leveraged contact spring arms and optimized force distribution.
Implementation Method 1
an overspring surrounding the base part at least in the area of the contact spring arm and applying a spring force to the contact spring arm
Implementation Method 2
The overspring is in engagement with the contact arm in an engagement area, which lies between the contact areas as seen in the insertion direction. This achieves a certain leverage of the contact spring arm
Data Source
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AI summary
The element has a base part comprising a contact spring arm (18), and an upper spring (12) impacting the contact spring arm with spring force. The contact spring arm surrounds the base part in an area of the contact spring arm. The contact spring arm comprises two contact areas for contacting of inserted plug contacts. The spring arm stands in contact with the contact spring arm in an engagement area (62), where the spring arm lies between the contact areas, when seen in the insertion direction. The base part and the upper spring are designed as a punching-/bending part.