Electrical Terminal Socket Section One-Piece Design
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Solution Overview
Problem
The production of existing electrical connection elements with a socket section and a separate overspring is economically costly and complex, requiring increased material input and production time.
Innovation Solution
A one-piece design for the socket section, where contact spring arms and a locking tongue are integrated into a stamped and bent part, eliminating the need for a separate overspring, thereby reducing material usage and production time while providing overbending protection to ensure reliable function.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a two-part design with separate overspring and base part is used, then the connection element can be produced with conventional methods, but the production cost increases and production speed decreases
Solution Approach 1:
The patent merges the overspring and base part into a single integrated socket section made from one piece of sheet metal. The contact spring arms and locking tongue are formed as integral parts of the same blank, eliminating the need for separate components and assembly operations. This resolving the contradiction by simplifying the structure while enabling more efficient production through stamping and bending processes.
2Reliability
If a separate overspring is attached to the base part, then the locking tongue and contact spring arms can be provided, but material input increases and production time increases
Solution Approach 1:
The socket section is formed as a monolithic structure from a single sheet metal blank, where the contact spring arms and locking tongue are integral features rather than separate components. This eliminates redundant material and assembly steps while ensuring reliable mechanical connection between all functional elements, as they are permanently bonded through the stamping and bending process.
3Productivity
If the socket section is designed as one piece, then production cost decreases and production speed increases, but overbending protection must be integrated
Solution Approach 1:
The socket section is segmented into functional zones within the single blank: contact spring arms for electrical connection, locking tongue for mechanical retention, and protective tabs for overbending protection. Each zone is formed by specific bending operations during manufacturing, allowing the integrated structure to provide multiple functions including built-in protection without requiring additional components.
4Reliability
If protective tabs are bent over to provide overbending protection, then contact spring arms are protected from damage, but the structure becomes more complex
Solution Approach 1:
The protective tabs are pre-formed as integral features of the socket section during the stamping and bending process, positioned to protrude beyond the contact spring arms before assembly. This preliminary formation of protection elements ensures that overbending protection is inherently built into the structure, preventing damage to contact spring arms during insertion without requiring complex additional components or assembly steps.
Data Source
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AI summary
The invention relates to an electrical connection element with a socket section for receiving a plug contact, wherein the socket section comprises two contact spring arms for contacting the plug contact received in the socket section and an outwardly bent locking tongue for locking the connection element in a housing. The invention further relates to a method for manufacturing an electrical connection element.