Contact Assembly Fasteners for Connector Alignment
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Solution Overview
Problem
Electrical contacts in connectors often experience misalignment and disengagement due to interference fits, leading to poor connections and potential damage from shorts.
Innovation Solution
The use of contact fasteners, such as apertures or protrusions, on both the electrical contact and the contact hood, which securely engage to prevent misalignment and disengagement, ensuring proper retention within the connector hood.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an interference fit is used to retain the electrical contact in the contact hood, then the contact is secured within the housing, but the contact is subject to misalignment and movement within the hood
Solution Approach 1:
The retention mechanism is segmented into multiple discrete fasteners (at least two hood fasteners and contact fasteners) distributed around the contact hood. This segmentation allows each fastener to independently secure the contact while collectively maintaining precise alignment, resolving the contradiction between retention strength and alignment precision.
Solution Approach 2:
The contact fasteners act as intermediary elements between the contact and the hood fasteners. These fasteners engage with both components, providing a precise mechanical interface that ensures accurate alignment while transferring retention forces, thereby simultaneously achieving secure retention and precise alignment.
2Strength
If an interference fit is used to secure the electrical contact, then the contact is retained in the hood, but the contact may become disengaged and cause shorts
Solution Approach 1:
The retention system uses multiple segmented fasteners distributed around the contact hood rather than a single interference fit. This segmentation provides redundant retention points, ensuring that if one fastener fails, the contact remains secured and cannot disengage to cause shorts, thereby improving reliability while maintaining retention strength.
Solution Approach 2:
The contact fasteners provide beforehand cushioning by pre-establishing precise mechanical engagement features that guide and constrain the contact during insertion. This prevents misalignment and ensures proper positioning before electrical connection is made, preventing shorts and improving reliability.
3Manufacturing precision
If multiple fasteners are used to secure the contact, then alignment and retention are improved, but the device complexity increases
Solution Approach 1:
The contact fasteners and hood fasteners are merged into a single integrated retention system. The contact fasteners are formed as integral parts of the contact assembly, and the hood fasteners are formed as integral parts of the contact hood, combining multiple functions into unified components that reduce overall structural complexity while maintaining precise alignment.
Solution Approach 2:
The fasteners are designed to self-align and self-secure during the insertion process. The geometric features of the fasteners automatically guide the contact into proper alignment with the hood, eliminating the need for additional alignment mechanisms or complex assembly procedures, thereby reducing device complexity while maintaining manufacturing precision.
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 solution provides stable and secure retention of electrical contacts, preventing misalignment and disengagement, thus ensuring reliable connections and preventing damage from shorts.
Implementation Method 1
The at least two hood fasteners engage the at least two contact fasteners to secure the electrical contact within the contact hood
Data Source
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AI summary
An electrical contact assembly is provided. The assembly includes a contact hood (180) having a body (186) including an axis (200) and an opening (60) extending through the body (187) along the axis (200). The opening (60) has an inner surface. The contact hood (180) is configured to be received in an opening (60) of a connector housing (52). At least two protrusions are formed on the inner surface of the contact hood opening. An electrical contact (104) is provided having a body (186) including a contact end (108) and a socket end (110). The socket end (110) is inserted axially into the opening (60) of the contact hood (180). The contact end (108) of the electrical contact (104) is configured to extend from a mating end (54) of the connector housing (52). At least two apertures are formed on the socket end (110) of the electrical contact (104). The at least two protrusions are received in the at least two apertures to secure the electrical contact (104) within the contact hood (180).