Flattened Connector Contact Elements for Easier Multi-Cable Soldering

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Solution Overview

Problem

Existing connectors with multiple contact elements and cables require complex and unreliable soldering processes that affect electrical properties, especially when cables are twisted together.

Innovation Solution

The contact element system features parallel, flat-surfaced contact elements with adaptable structures that allow for simplified soldering from multiple directions and maintain consistent electrical properties by adjusting capacitance and impedance through modification of adaptation structures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a conventional solder cup design is used, then the electrical conductor must be inserted from a specific direction, but this increases the complexity and difficulty of soldering multiple cables

Engineering Contradiction:

Improveease of solderingVSAvoidsoldering process complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent inverts the conventional solder cup design by providing a flattened axial end section instead of a hollow cylindrical cup. This allows the electrical conductor to be soldered from the end of the contact element body rather than inserting into a cup from the side, enabling conductors to be guided from above or laterally to the soldering connection.

Inventive Principle:

Principle #13The other way round (Inversion)

2Productivity

If multiple contact elements are arranged parallel to one another with conventional solder cups, then the cable must be extensively unwound and exposed, but this increases the length of cable required and complicates the soldering process

Engineering Contradiction:

Improvesoldering efficiencyVSAvoidcable length required

Core Design Contradiction:

ProductivityVSLength of moving object

Solution Approach 1:

The flattened axial end section allows conductors to remain twisted as far as possible and be soldered from the end of the contact element body, requiring exposure of only a small end section of the cable instead of extensive unwinding.

Inventive Principle:

Principle #13The other way round (Inversion)

3Reliability

If the contact element body is made from copper alloys, then good electrical conductivity is achieved, but the material selection becomes more complex

Engineering Contradiction:

Improveelectrical conductivityVSAvoidmaterial selection flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent specifies that the contact element body is made from copper and/or copper alloys, particularly copper-beryllium (CuBe), bronze (CuSn), and/or brass (CuZn), allowing optimization of electrical conductivity and mechanical properties through material composition parameters.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP4250491B1Contact element system and plug connector

Publication Date: 2026.04.29 YAMAICHI ELECTRONICS DEUTSCHLAND GMBH

Figure 1a~1c
Figure 2a~2d
Figure 3a~3b

AI summary

The invention relates to a contact element (10a) for a connector (100), a contact element system (50), and a connector (100). The contact element (10a) for a connector (100) comprises a conductive cylindrical contact element body (1a), wherein an axial end section (E2) of the contact element body (1a) is flattened and has a substantially flat surface (F2) for soldering an electrical conductor.