Flat Contact with Integrated Press-Fit for PCB Interfacing
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Solution Overview
Problem
Existing electrical connection elements for printed circuit boards are limited to specific types of contacts, such as fork contacts or direct press-fit contacts, making standardization across series of similar electrical components, like stators for electric motors, difficult.
Innovation Solution
A connecting element with a flat contact having two plane-parallel surfaces for a fork-shaped mating contact and a press-fit contact formed in one piece, allowing for both direct and indirect electrical contact with the circuit board, and capable of being used simultaneously, with the press-fit contact formed on an end face of the flat contact and housed in an insulating body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a connection element uses only fork contacts or only press-fit contacts, then the electrical contact type is standardized, but the adaptability to different contact methods is limited
Solution Approach 1:
The connection element is designed with both a flat contact for fork-shaped mating contacts and at least one press-fit contact formed in one piece with the flat contact. This multi-functional design allows the same connection element to accommodate both fork contact and direct press-fit contact methods, eliminating the need for different connection element variants and enabling standardization across series of electrical components.
2Adaptability or versatility
If a connection element provides both fork contact and press-fit contact options, then the versatility is enhanced, but the manufacturing complexity increases
Solution Approach 1:
The press-fit contact is formed in one piece with the flat contact as an integrated structure. This merging of multiple contact types into a single manufactured component simplifies the manufacturing process compared to assembling separate fork contact and press-fit contact elements, while still providing both contact method options.
3Power
If the press-fit contact is formed on an end face of the flat contact, then the current carrying capacity is enhanced, but the space requirements increase
Solution Approach 1:
The press-fit contact is formed on an end face of the flat contact, utilizing the three-dimensional space of the connection element. This dimensional arrangement allows multiple contact functions to be packed into a compact structure, enhancing current carrying capacity through multiple contact points without proportionally increasing the overall footprint of the connection element.
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The element (1) has a flat contact (3) with two freely accessible, plan-parallel contacting areas (4) to retain a fork-shaped counter-contact. A press fit contact (6) is formed at a front end (7) of the flat contact, which is formed as a blade contact. The counter-contact is attached with springs and the contacting areas. The element is held in an insulating body (9), where the flat contact protrudes from the insulating body. The press fit contact is formed at the body opposite to front end (8) of the flat contact, and comprises two legs (14) with a flattened outer contour.