End-Face Contact Element Structure for Stable High-Cycle Mating
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Solution Overview
Problem
Existing end-face contact elements for plug connectors are costly to manufacture in large quantities and lack mechanical stability, making them unsuitable for high-numerity mating cycles.
Innovation Solution
The development of an electrical contact element formed from a stamped and bent part or a deep-drawn metal component, featuring a contact area with an end-face contact surface and a support area for enhanced mechanical stability, allowing for cost-effective mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If end-face contact elements are designed as solid turned parts to ensure robustness and durability, then mechanical stability is improved, but manufacturing cost and material cost increase significantly
Solution Approach 1:
The patent applies this principle by using a thin-walled hollow cylindrical shell structure instead of a solid turned part. The hollow cylindrical shell maintains sufficient mechanical stability for end-face contacting while dramatically reducing material consumption and manufacturing cost, enabling cost-effective mass production of robust contact elements
Solution Approach 2:
The patent segments the contact element into distinct functional areas: a contact area with end-face contact surface for electrical contacting, and a support area for mechanical stability. This segmentation allows optimization of each area independently, achieving robustness where needed while minimizing material usage overall
2Reliability
If end-face contact elements are designed as solid turned parts to ensure durability for high mating cycles, then reliability is improved, but weight increases
Solution Approach 1:
The hollow cylindrical shell structure provides the necessary durability for high mating cycles while significantly reducing weight compared to solid turned parts. The thin-walled design maintains structural integrity through its geometric configuration rather than material volume
3Ease of manufacture
If stamping and bending processes are used to manufacture contact elements cost-effectively, then ease of manufacture is improved, but mechanical stability deteriorates
Solution Approach 1:
The invention specifically addresses this contradiction by using a thin-walled hollow cylindrical shell that can be manufactured via stamping and bending processes. The hollow shell geometry provides enhanced mechanical stability despite the thin-walled construction, making the contact element suitable for end-face contacting while maintaining cost-effective manufacturability
Solution Approach 2:
The patent transitions from two-dimensional stamped sheets to three-dimensional hollow cylindrical shell structures. This dimensional change provides mechanical stability through volumetric geometry while still utilizing cost-effective stamping and bending manufacturing processes
Data Source
AI summary
An electrical contact element (3) is formed from a stamped and bent part and/or from a deep-drawn metal component (1). The electrical contact element (3) has a contact area (6) having an end-face contact surface (7) designed for electrical and mechanical contacting with an electrical mating contact element. The electrical contact element (3) also has a support area (8), which is arranged on a side of the contact area (6) facing away from the end-face contact surface (7) and is designed so as to mechanically support the contact area (6). It is provided that the contact area (6) is integrally connected to the support area (8) via a primary connecting section (9).