Extruded Socket Contact Lamellae for Faster Precision Manufacturing
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Solution Overview
Problem
The production of socket contacts is time-consuming and costly due to traditional machining methods, and existing multi-component designs are complex and voluminous, making them unsuitable for compact applications.
Innovation Solution
A method using extrusion to produce a hollow cylindrical contacting area with contact lamellae directly formed during the process, eliminating the need for machining and allowing for improved spring properties and material utilization, with a crimp connection area for efficient conductor connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional machining methods are used to produce socket contacts, then manufacturing precision can be achieved, but production time increases and productivity decreases
Solution Approach 1:
The patent replaces traditional mechanical machining operations (milling, drilling) with a hydroforming process that uses fluid pressure to directly form the contact blades and hollow cylindrical structure. This substitution of mechanical removal processes with a forming process using fluid pressure dramatically reduces production time while maintaining manufacturing precision through controlled material flow and forming parameters.
Solution Approach 2:
The patent utilizes phase transition of water between liquid and vapor states during hydroforming. The water is injected at high pressure and temperature, causing phase change that generates extreme pressure to form the complex geometry of the socket contact, including the hollow cylindrical contacting area and contact blades, in a single rapid operation rather than multiple machining steps.
2Force
If multi-component designs are used for socket contacts, then spring force can be adjusted, but device complexity increases and the structure becomes bulky
Solution Approach 1:
The patent merges the spring element and the contact structure into a single integrated component formed by hydroforming. The contact blades are formed as an integral part of the socket contact body, eliminating the need for separate spring components and fasteners. This merging reduces device complexity while maintaining the spring force function through the elastic deformation capability of the formed contact blades.
Solution Approach 2:
The patent adjusts spring force by changing geometric parameters of the contact blades during the hydroforming process, such as thickness, curvature, and dimensions of the hollow cylindrical contacting area. By modifying these parameters in the forming stage, the desired spring force is achieved without adding component complexity or bulk.
3Ease of manufacture
If traditional machining methods are used, then contact blades can be created, but material utilization decreases and costs increase
Solution Approach 1:
The patent changes the manufacturing approach from material removal (machining) to material forming (hydroforming). By controlling parameters such as fluid pressure, temperature, and forming time, the process directly shapes the contact blades and hollow structure from the original material, maximizing material utilization and eliminating waste associated with machining operations.
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
Significantly reduces production time and costs, enhances spring properties, and increases productivity while maintaining high dimensional accuracy and surface quality, enabling cost-effective and compact socket contacts with improved current-carrying capacity.
Implementation Method 1
the material of the round bar is displaced such that it flows into the cavities formed in the punch opposite to the direction of movement of the punch
Implementation Method 2
a hollow cylindrical contacting region is produced at a first end of the round bar by means of extrusion
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a socket contact (1) and to a method for producing a socket contact (1) from a round bar (13), comprising the following steps: • producing a hollow cylindrical contacting region (2) at a first end (3) of the round bar (12), by means of extrusion, said hollow cylindrical contacting region (2) having contact segments (4) which extend in the longitudinal direction (L) of the contacting region (2) and are separated from one another in the peripheral direction of the hollow cylindrical contacting region (2) by means of recesses (5), said recesses (5) being produced during extrusion.