Electrical Contact Locking Arm Vertical Movement
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Solution Overview
Problem
Miniaturization of electrical connectors leads to increased influence of forces acting on cables, compromising the locking and electrical connection reliability, especially in environments like the automotive industry where connectors must function in hot, contaminated, or chemically aggressive conditions.
Innovation Solution
An electrical contact design featuring a contact body with an integrated contact spring and a locking arm that moves vertically to resist withdrawal forces, with a bending point position optimized for elastic and plastic deformation to enhance mechanical resistance and secure the cable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If electrical connectors are miniaturized to save space, manufacturing costs, and weight, then the size of electrical connectors is reduced, but forces acting on cables increasingly influence the locking of the contact within the housing, compromising connection reliability
Solution Approach 1:
The locking arm is designed as a resilient (elastic) component that can dynamically adapt to forces acting on the cable. When withdrawal forces are applied, the locking arm moves vertically away from the contact body in a controlled manner, allowing the system to absorb and respond to dynamic loads rather than being rigidly fixed, thus maintaining reliability despite miniaturization
Solution Approach 2:
The invention changes the physical state and mechanical properties of the locking arm by designing it with specific elastic characteristics. The locking arm's resilience allows it to deform elastically under load and return to its original position, changing the mechanical parameter of stiffness to achieve both miniaturization and maintained locking reliability
2Strength
If the locking arm is designed to move vertically away from the contact body under withdrawal force, then mechanical resistance to cable pull is improved, but the structural complexity of the contact assembly increases
Solution Approach 1:
The locking arm is integrated as part of the contact spring assembly rather than being a separate component. The locking arm merges the functions of electrical contact (through the contact spring) and mechanical locking (through the vertical movement capability) into a single integrated structure, reducing overall device complexity while maintaining strength
Solution Approach 2:
The locking arm serves multiple functions: it provides the electrical contact path through the contact spring, provides mechanical locking by engaging with the housing, and resists withdrawal forces through its resilient vertical movement. This multi-functionality reduces the need for separate components, thereby reducing structural complexity while maintaining mechanical resistance
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 design effectively resists withdrawal forces on cables, ensuring reliable electrical connections and improved mechanical resistance, even under adverse environmental conditions, while maintaining cost-effectiveness.
Implementation Method 1
The locking arm moves in a vertical direction away from the contact body when a withdrawal force acting on the contact spring exceeds a retaining force of the contact spring
Data Source
AI summary
An electrical contact includes a contact body and a contact spring. The contact spring is disposed in the contact body and has a locking arm locking the contact spring in a housing. The locking arm moves in a vertical direction away from the contact body when a withdrawal force acting on the contact spring exceeds a retaining force of the contact spring.