Electrical Connector With Segmented Contact Arm
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Solution Overview
Problem
Existing electrical connection elements fail to provide a reliable and durable connection under strong vibrations and extreme temperatures while allowing easy plugging and high current conductivity over the service life.
Innovation Solution
An electrical connection element with a base body and socket section featuring a contact arm divided into partial contacts, supported by an overspring arm made of stainless steel or spring steel, which enhances contact reliability through redundant contacting and elasticity, and a guide tab for easy insertion and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single contact arm is used for contacting the plug contact, then the device complexity is reduced, but the reliability of electrical connection deteriorates under vibrations and temperature fluctuations
Solution Approach 1:
The contact arm is divided into multiple partial contacts (at least two) that are arranged alongside each other. This segmentation increases the reliability of electrical connection because if one partial contact loses contact force due to vibrations or temperature changes, the other partial contacts maintain the electrical connection. The segmentation allows redundant contacting without significantly increasing overall device complexity.
2Reliability
If the contact arm is made from high-strength material to maintain contact force, then the reliability is improved, but the manufacturing cost increases
Solution Approach 1:
By dividing the contact arm into multiple partial contacts, the patent enables the use of less expensive materials. The redundant structure of multiple partial contacts compensates for the lower individual strength of each contact, maintaining overall contact force stability and reliability while reducing manufacturing costs compared to using a single high-strength contact arm.
Solution Approach 2:
The patent changes the structural parameter from a single contact arm to multiple partial contacts, which alters the mechanical properties of the system. This parameter change allows the use of materials with different strength characteristics while maintaining the required contact force through the combined effect of multiple contacts.
3Reliability
If the contact arm is designed with high elasticity to withstand vibrations, then the reliability is improved, but the device complexity and material requirements increase
Solution Approach 1:
The overspring acts as an intermediary element that provides elastic support to the contact arm. The overspring with its arms creates a spring support system that absorbs vibrations and maintains contact force without requiring the contact arm itself to be highly elastic or complex. This intermediary structure protects the contact arm while providing the necessary resilience.
4Ease of operation
If the insertion opening is made large to allow easy plugging, then the ease of operation is improved, but the contact precision and secure latching deteriorate
Solution Approach 1:
The guide tab creates a guiding effect that aligns the plug contact with the insertion opening during the plugging process. This guiding mechanism ensures that even with a relatively large insertion opening for easy access, the plug contact is properly positioned and aligned, maintaining contact precision and secure latching while preserving ease of operation.
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 solution ensures a reliable and durable electrical connection that withstands vibrations and temperature fluctuations, reduces the risk of contact force relaxation, and allows for cost-effective production with less expensive materials, while facilitating easy plugging and secure latching.
Implementation Method 1
the contact arm can be deflected against a restoring force of the overspring arm. The Überfederarm thus creates a kind of spring support for the contact arm
Data Source
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AI summary
The element has a base body comprising a connection section and a socket section (12). The socket section comprises a contact arm (28) for contacting a plug contact. An additional spring (16) encloses the body in an area of the socket section and acts together with the arm in the contact area such that the spring is deflected against resetting force of an additional spring arm (34). The spring has a guiding latch (24) in an area of an insertion opening (26) for the contact. The guiding section overlaps with an end area of the arm and outwardly preloads the arm. The base body and/or the spring is designed as a press-bent-part.